WO2014073352A1 - Coil and fabrication device therefor, and coil fabrication method - Google Patents

Coil and fabrication device therefor, and coil fabrication method Download PDF

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Publication number
WO2014073352A1
WO2014073352A1 PCT/JP2013/078292 JP2013078292W WO2014073352A1 WO 2014073352 A1 WO2014073352 A1 WO 2014073352A1 JP 2013078292 W JP2013078292 W JP 2013078292W WO 2014073352 A1 WO2014073352 A1 WO 2014073352A1
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WO
WIPO (PCT)
Prior art keywords
winding
metal sheet
bending
coil
wound
Prior art date
Application number
PCT/JP2013/078292
Other languages
French (fr)
Japanese (ja)
Inventor
祐介 逵村
Original Assignee
東芝産業機器システム株式会社
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Filing date
Publication date
Application filed by 東芝産業機器システム株式会社 filed Critical 東芝産業機器システム株式会社
Priority to EP13853614.9A priority Critical patent/EP2919242B1/en
Priority to ES13853614T priority patent/ES2730687T3/en
Priority to CN201380058369.1A priority patent/CN104798151B/en
Priority to RU2015121638A priority patent/RU2611723C2/en
Publication of WO2014073352A1 publication Critical patent/WO2014073352A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/071—Winding coils of special form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/077—Deforming the cross section or shape of the winding material while winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/096—Dispensing or feeding devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation

Definitions

  • Embodiments of the present invention relate to a coil, an apparatus for manufacturing the same, and a method for manufacturing the coil.
  • the coil manufacturing apparatus of the present embodiment includes a feeding means for feeding the metal sheet from a wound body in which a band-like metal sheet is wound, and a winding type for winding and winding the metal sheet fed from the feeding means. And a feeder provided between the feeding means and the winding form for feeding the metal sheet fed out by the feeding means to the winding form, and the winding of the metal sheet sent by the feeder.
  • Bending means that performs bending before winding into a mold, and the metal sheet, the start of winding on the winding mold has a shape according to the outer peripheral shape of the winding mold, and thereafter, the metal sheet is lap wound on the winding mold
  • Control means for controlling the bending process of the bending means based on the feed amount of the metal sheet by the feeder so that the shape conforms to the outer peripheral shape of By controlling the more the bending, the winding amount curl depending on the metal sheet in the wound-type, characterized by being configured to impart the winding prior to the former.
  • FIG. 1 showing a first embodiment, is a conceptual diagram for explaining the overall configuration of a coil manufacturing apparatus.
  • Block diagram showing the electrical configuration The perspective view which shows the structure of a coil typically The structure of another coil is schematically shown, and (a) is a side view of an octagonal coil when viewed from the axial direction of the winding form, (b) to (d) are provided with cooling ducts of various forms.
  • reference numerals 1, 101 to 104 denote coils
  • 2 denotes a metal sheet
  • 11 denotes a wound body
  • 12 denotes a feeding means
  • 13 denotes a leveler
  • 14 denotes a feeder
  • 16, 30 denotes a winding type
  • 15, 31 denotes bending means
  • 20 Indicates a control means.
  • the coil 1 manufactured is formed by winding a metal sheet 2 in the form of a strip and an insulating sheet 3 in the form of the strip in the form of multiple layers around a winding form (see reference numeral 16 in FIG. 1).
  • a square tube shape is formed as a whole.
  • the metal sheet 2 is a thin metal plate made of, for example, aluminum, and the insulating sheet 3 is, for example, an insulating sheet.
  • the coil 1 is formed so that there is no deviation in the width direction of the metal sheet 2 indicated by reference numeral W in FIG. 3 and no gap is generated between the layers wound in multiple layers.
  • the metal sheet 2 may be formed of another metal material such as copper.
  • reference numeral 11 denotes a wound body in which a metal sheet 2 is wound in advance in a hoop shape
  • reference numeral 12 denotes an uncoiler for feeding the metal sheet 2
  • reference numeral 13 denotes a winding of the metal sheet 2.
  • Reference numeral 14 denotes a leveler for correcting, a feeder for intermittently feeding the metal sheet 2
  • reference numeral 15 denotes a bending device as bending means for the metal sheet 2.
  • the wound body 11 is the metal sheet 2 as a hoop material wound in a hoop shape in advance, and is mounted to the mounting portion 12 a of the uncoiler 12.
  • the uncoiler 12 rotatably supports the wound body 11 at the mounting portion 12a, and the feeding means for drawing out the metal sheet 2 by the rotation of the wound body 11 in the direction opposite to the winding direction. Is configured as.
  • the leveler 13 includes a plurality of work rolls 13a, 13b, and 13c which are provided on the side of the unwinding direction from the uncoiler 12 and are arranged in a zigzag as shown in FIG.
  • the curl in the fed-out metal sheet 2 is corrected by being passed between the upper and lower work roll groups 13a to 13c.
  • the feeder 14 performs an intermittent feeding operation of repeating feeding and stopping of the metal sheet 2 whose curl is removed by the leveler 13 toward the bending device 15.
  • the feeder 14 includes, for example, a pair of rolls 14a and 14b for holding the metal sheet 2 and a motor 14c (see FIG. 2) for driving the rolls 14a and 14b.
  • the motor 14c is constituted by, for example, a servomotor, and an encoder 14d (see FIG. 2) for detecting the amount of rotation is attached and feedback-controlled.
  • the feed amount of the metal sheet 2 by the feeder 14 is calculated by a control device 20 described later based on a detection signal of the encoder 14 d and the like.
  • the rolls 14a and 14b of the feeder 14 are disposed close to the front side in the conveying direction with respect to the bending device 15 (a position near the entrance side of the bending device 15) so that forming errors of the bending rod do not occur with the bending device 15.
  • the rolls 14a and 14b are made of, for example, a material (surface shape) having a large frictional resistance between the rolls 14a and 14b and the metal sheet 2 with respect to the material (and shape) of the surface thereof.
  • the bending device 15 is disposed between the feeder 14 and the winding die 16 and performs bending on the metal sheet 2 before winding it on the winding die 16.
  • the bending device 15 includes a bending die 17a and a pressing mechanism 17b which bends the metal sheet 2 so as to plastically deform the metal sheet 2 at a predetermined angle along the bending die 17a.
  • Various bending dies 17a are prepared according to the outer peripheral shape of the winding die 16 or the shape of the coil 1 to be manufactured, and the pressing mechanism 17b is in contact with the metal sheet 2 in the thickness direction of the metal sheet 2.
  • the metal sheet 2 of the coil 1 Due to the relative advancing and retracting motion between the bending die 17a and the pressing mechanism 17b, the metal sheet 2 of the coil 1 is bent at, for example, 90 degrees when viewed from the width direction (vertical direction to the paper of FIG. 1). It is formed.
  • the bending device 15 forms a widthwise extending fold (folding crease) corresponding to the corner of the former 16 or the corner of the metal sheet 2 wound on the latter.
  • the bending device 15 forms a bending wedge at 45 degrees with respect to the metal sheet 2, and the metal sheet 2 according to the shape and size of the duct 18 in the coils 103 and 104. Form a fold weir so that there is no gap between the two layers.
  • the winding form 16 winds the metal sheet 2 and the insulating sheet 3 while rotating around the rotation axis 16a.
  • Various types of winding dies 16 are prepared according to the shape and size of the coil 1 (the dimensions in the longitudinal direction and the lateral direction, the width dimension W of the metal sheet 2 in FIG. 3, etc.).
  • the winding die 16 shown in FIG. 1 has a square cylindrical shape whose outer peripheral shape is square when viewed from the axial direction of the rotation shaft 16a (the direction perpendicular to the sheet of the drawing).
  • the winding form of each coil 101 to 104 shown in FIG. 4 is an octagonal cylinder whose outer peripheral shape is octagonal when viewed from the axial direction of the rotary shaft 16a.
  • the rotating shaft 16a of the winding form 16 is rotationally driven by a motor 16c (see FIG. 2) as a driving means. As the motor 16c is driven, the metal sheet 2 and the insulating sheet 3 are simultaneously wound around the winding die 16 to be wound in multiple layers.
  • the duct for cooling is disposed, for example, in a predetermined layer of the metal sheet 2 (insulation sheet 3) wound in multiple layers when manufacturing octagonal cylindrical coils 102 to 104.
  • the ducts 18 of the coils 103 and 104 shown in FIGS. 4C and 4D include a rod-shaped duct piece 18a made of an insulating material and a mount 18b as a mounting member.
  • the duct pieces 18a are arranged in a fixed manner at predetermined intervals with respect to the backing sheet 18b, and have an integrated configuration.
  • the duct 18 is provided on a duct insertion layer I preset for each of the coils 103 and 104, such as an adhesive or adhesive on the mount 18b. It is fixed by the fixing means.
  • a duct insertion layer I preset for each of the coils 103 and 104, such as an adhesive or adhesive on the mount 18b. It is fixed by the fixing means.
  • an arrangement space for the duct 18 in the duct insertion layer I is formed in the upper side portion, the lower side portion and both side portions in FIG.
  • an arrangement space for the duct 18 in the duct insertion layer I is formed at the upper side and the lower side in FIG. 4 (d).
  • the arrangement space for the duct 18 is formed such that the metal sheet 2 and the duct 18 are in close contact with each other in accordance with the shape and size of the duct 18, so the heat radiation effect of the metal sheet 2 is enhanced. Further, in the duct insertion layer I, the portion not provided with the duct 18 is provided with the bending crease by the bending device 15 so that no gap is generated. For this reason, even if the arrangement space for the duct 18 is provided, it is possible to prevent the space (particularly, the corner portion) from becoming a weak point, and short circuit mechanical force, that is, short circuit current flows as the coils 103 and 104 as a whole. It is excellent in the mechanical force etc. which act when it
  • the duct 19 of the coil 102 shown in FIG. 4B is, for example, a corrugated duct formed in a corrugated shape.
  • an arrangement space for the duct 19 in the duct insertion layer I is formed over the entire circumference thereof. Since the arrangement space for the duct 19 is also formed in accordance with the shape and size of the duct 19, as described above, the heat radiation effect can be high and the mechanical characteristics can be excellent.
  • the shape and arrangement of the ducts may be changed as appropriate, such as disposing a duct 18 having a rod-shaped duct piece 18a instead of the corrugated duct 19 for the coil 102. Further, the shape of the entire coil may be changed as appropriate, for example, a square cylindrical shape as in the coil 1 of FIG. 3 or an octagonal cylindrical shape as in the coils 101 to 104 of FIG.
  • FIG. 2 is a block diagram showing a configuration of a control system related to the manufacture of the coils 1, 101 to 104.
  • the control device 20 is mainly configured of a microcomputer, and is a control unit having a storage unit 21 including a CPU, a ROM, a RAM, and a non-volatile memory.
  • the control device 20 is connected to the encoder 14d and an operation input unit 22 for inputting various operation signals from key switches (not shown) of the operation panel.
  • the control device 20 is also connected to various detection sensors 23 including a detection sensor provided near the winding die 16 to detect the winding state of the metal sheet 2.
  • a sheet detection unit for detecting an end portion of the metal sheet 2 at the beginning of winding, or a plate thickness detection unit for detecting a thickness dimension of the metal sheet 2 may be provided.
  • drive circuits 24, 25 and 26 for driving the motor 14c for the feeder 14, the pressing mechanism 17b, and the motor 16c for the winding die 16 are connected to the control device 20.
  • coil information on the coils 1, 101 to 104, duct information on the ducts 18, 19 and the like are stored in advance.
  • the coil information is, for example, in the case of the coil 1, the thickness of the metal sheet 2 in addition to the shape and dimensions (long side dimension in the vertical direction and short side dimension in the horizontal direction in FIG. 3) It includes information such as dimensions and is defined for each coil 1, 101 to 104.
  • the duct information includes positional information of the installation space in each of the coils 102 to 104 in addition to the dimensions of the ducts 18 and 19, and is defined in association with the coil information.
  • the coil information and the duct information may be set based on the operation of the operation input unit 22 by the operator as described in the following description of the operation, or even if the thickness dimension is acquired from the detection sensor 23 Good. Then, the control device 20 controls various actuators such as the motors 14c and 16c and the pressing mechanism 17b based on the above information, and causes the winding die 16 to automatically execute the winding operation of the metal sheet 2 There is.
  • the wound body 11 of the metal sheet 2 is attached to the mounting portion 12a of the uncoiler 12 in advance, and the winding end end side of the wound body 11 is fed out to pass through the leveler 13, the feeder 14 and the bending device 15 It shall be set to send to the 16 side.
  • the winding end end of the winding body 11 is the winding start end to the winding die 16.
  • the wound body 11 'of the insulating sheet 3 is mounted on a mounting portion 12a' different from the wound body 11, and is set to be fed from the feeding means 12 'to the winding die 16 side.
  • the operator operates the operation input unit 22 to select the type of the coils 1, 101 to 104 to be manufactured, or set the coil information and the duct information. Then, when the start switch of the operation input unit 22 is operated, the metal sheet 2 is drawn out from the wound body 11 and the intermittent feeding operation by the feeder 14 is performed. In this case, the metal sheet 2 fed out from the wound body 11 is passed between the upper and lower work roll groups 13a to 13c by the leveler 13 so that the internal strain is removed and the curl is corrected to be flat. .
  • control device 20 calculates the feed amount of the metal sheet 2 based on the detection signal of the encoder 14d for the motor 14c for the feeder 14, and based on the coil information, It is intermittently driven so as to form a bending rod corresponding to the corner of the metal sheet 2 to be lap-wound on the winding die 16.
  • the feed amount in this feed stroke will be described in detail on the assumption of a specific example.
  • the winding start end to the winding form 16 shown by P0 in the same figure is fixed to the corner of the winding form 16.
  • the winding die 16 having a rectangular shape when viewed from the axial direction has a short side dimension of M1 and a long side dimension of M2.
  • the control unit 20 based on the coil information, a drive signal to the motor 14c for the feeder 14 to feed amount L 1 are the same M1 and short side dimension from the winding beginning end P0 of the former 16 Output.
  • control device 20 moves the pressing mechanism 17b forward and backward toward the bending die 17a in a state where the motor 14c is stopped (bending stroke).
  • the metal sheet 2 is formed with a 90-degree bent portion at a position of P1 separated from the winding start end P0 by M1 minutes (see FIG. 3).
  • control device 20 drives the motor 14c so that the second side feed amount L2 becomes M2 equal to the long side dimension of the winding die 16, and then moves the pressing mechanism 17b forward and backward. Thereby, a 90 ° bent portion is formed on the metal sheet 2 at a position P2 separated from the bent portion P1 by M2.
  • the feed amounts L 1 , L 2 and L 3 by the feeder 14 correspond to the corners of the form 16 respectively.
  • the bending portions are set to M1, M2 and M1 and bending is performed each time the driving of the motor 14c is stopped, thereby forming the plastically deformed bent portions P1, P2 and P3.
  • the motor 16 c for the form 16 is driven to synchronize with the motor 14 c for the feeder 14. Therefore, even when the torque of the motor 16c for the winding form 16 is relatively small, the metal sheet 2 is wound along with the insulating sheet 3 so as to be in close contact with the outer peripheral surface of the winding form 16 and a 90 ° bent portion Also in P1 to P3, no gap is generated between it and the corner of the mold 16.
  • the motor 14c is driven such that
  • the control device 20 feeds the feed amounts L 5 , L 6 , L 6 of the metal sheet 2 by the feeder 14 so that the shape conforms to the outer peripheral shape of the metal sheet 2 to be wound in an overlapping manner on the winding die 16 via the insulating sheet 3.
  • L N , L N + 1 ,... are set (see FIG. 1). That is, the control device 20 takes the sheet materials 2 and 3 already taken up based on the coil information such as the dimensions M1 and M2 of the winding die 16 and the thickness of the metal sheet 2 (and the insulation sheet 3). The feed amount L 5 ⁇ in anticipation of the thickness of is calculated.
  • the coil 1 wound in multiple layers does not have a gap between the layers, and has high dimensional accuracy and excellent short circuit mechanical force.
  • an octagonal cylindrical winding type (not shown) is used instead of the rectangular cylindrical winding type 16 unlike the coil 1 described above.
  • a bending die for forming a 45-degree bent portion is used in place of the bending die 17a for forming a 90-degree bending portion.
  • each of the attachment parts Ia and Ib (see FIG. 4D) of the duct insertion layer I in the metal sheet 2 controls the control device 20 based on the coil information, the duct information, and the integrated value of the feed amount.
  • the driving of the feeder 14 is temporarily stopped before being wound in an overlapping manner.
  • each duct 18 prepared in advance is attached and fixed to each of the attached parts Ia and Ib manually (it may be automated).
  • the attached portions Ia and Ib in the metal sheet 2 are located closer to the winding die 16 than the feeder 14 and the bending device 15, and can identify the 45-degree bent portion as an index. It can be installed accurately.
  • the feed amount of the metal sheet 2 is set by the control device 20 so that the arrangement space for the duct 18 is formed in the upper side and the lower side in FIG. 4D.
  • the said bending part is formed so that the metal sheet 2 and the duct 18 may closely contact according to the shape dimension of the duct 18, the heat dissipation effect of the metal sheet 2 is heightened.
  • the coil 104 wound in multiple layers does not have a gap between the layers except for the installation space for the duct 18, and has high dimensional accuracy and a short circuit machine. It will be excellent in power.
  • coil information including the thickness of the metal sheet 2 and duct information, and the amount of winding in the winding type (the integrated value of the size of the winding type and the feed amount) Since the bending process is performed after the feed amount of the feeder 14 is calculated by the control device 20 based on the number of turns obtained from the above, dimensioning with high accuracy can be performed.
  • the manufacturing apparatus of the coils 1, 101 to 104 includes the feeder 14 for feeding the metal sheet 2 fed out by the feeding means to the winding die and the metal sheet 2 sent by the feeder 14
  • the bending device 15 which performs bending before winding into a winding die and the metal sheet 2 have a shape in which the winding start of the winding die is matched to the outer peripheral shape of the winding die,
  • a control device 20 for controlling bending of the bending device 15 based on the feed amount of the metal sheet 2 by the feeder 14 so that the shape conforms to the outer peripheral shape of the sheet 2.
  • a bending weir in accordance with the winding amount of the metal sheet 2 in the winding die is applied before the winding in the winding die.
  • the metal sheet 2 the bending crease according to the outer peripheral shape of the winding die and the winding amount to the winding die before winding up to the winding die. For this reason, with respect to the coils 1, 101 to 104 after being wound up, it is possible to reliably eliminate the winding expansion due to the spring back, and to improve the dimensional accuracy.
  • the metal sheet on the winding die side can not be wound with high accuracy, the metal sheet being wound may be shifted in the width direction and the winding may be interrupted. is there.
  • the metal sheet 2 regardless of the thickness and rigidity of the metal sheet 2, even if the winding torque of the winding mold is relatively small, the metal sheet 2 is accurately wound around the winding mold to prevent deviation. And can be excellent in manufacturing efficiency and quality.
  • the outer peripheral shape of the winding form is a polygon when viewed from the axial direction of the rotation shaft 16a, and the bending device 15 is a metal wound on the corner of the winding form or the winding form with respect to the metal sheet 2. It is configured to form a fold weir corresponding to the corner of the sheet 2. According to this, even in the case of polygonal coils 1, 101 to 104, the corner portion can be bent in advance to the plastic region by the bending device 15 in advance. Therefore, the gap between the layers at the corner can be surely eliminated, and dimensioning with high accuracy can be performed.
  • the metal sheet 2 and the ducts 18 and 19 are formed to be in close contact with each other according to the shape and size of the ducts 18 and 19. While being able to improve a heat dissipation effect, it can be excellent in short circuit mechanical force etc.
  • the feeder 14 and the bending device 15 are disposed close to each other in the manufacturing device. According to this, it is possible to minimize the forming error caused by the bending or the like of the metal sheet 2 between the feeder 14 and the bending device 15, and to further improve the dimensional accuracy.
  • the leveler 13 is provided between the feeding means and the feeder 14 and corrects the curl of the metal sheet 2 fed from the feeding means. According to this, the internal strain is removed by the leveler 13, and the curling can be corrected to be flat, and the coils 1, 101 to 104 with higher accuracy can be stably formed.
  • FIG. 5 shows a second embodiment.
  • the same reference numerals are given to the same parts as the parts described above, and the description thereof will be omitted.
  • the winding die 30 of the second embodiment has a cylindrical shape whose outer peripheral shape is annular in the axial direction of the rotation shaft 16a.
  • the bending device 31 as a bending means includes, for example, a plurality of forming rolls 31a to 31c, and forms a curved ridge corresponding to the curvature of the winding die 30 or the curvature of the metal sheet 2 wound on the winding die 30 in an overlapping manner. Is configured as.
  • data of the radius of curvature associated with the feed amount of the metal sheet 2 and the type of the winding die 30 is stored in advance in the storage unit 21 as coil information. Then, based on the data of the radius of curvature, the control device 20 superimposes the positions (for example, the positions in the vertical direction) of the forming rolls 31a to 31c illustrated in FIG. 5 on the outer shape of the winding die 30 or the winding die 30.
  • the feed amount is changed in conjunction with the feed amount so as to be bent to a shape that conforms to the outer shape of the wound metal sheet 2.
  • the feed amount may be continuous feed by the feeder 14 (not shown in FIG. 5) disposed close to the front side in the conveyance direction with respect to the bending device 31.
  • a servomotor and an encoder (both not shown) for driving any of the forming rolls 31a to 31c are attached, and the metal sheet 2 is sandwiched and driven with a predetermined pressure on the forming rolls 31a to 31c.
  • the same function as the above-mentioned feeder 14 may be given together by comprising.
  • a leveler may be disposed between the forming rolls 31a to 31c and the uncoiler 12 as in the first embodiment to remove internal strain in advance.
  • the metal sheet 2 is unwound from the wound body 11, and the continuous feeding operation by the feeder 14 (or the forming rolls 31a to 31c) is performed.
  • the metal sheet 2 is bent in the plastic region by the forming rolls 31a to 31c, so that the internal strain of the metal sheet 2 can be reduced.
  • control device 20 controls the bending process by the forming rolls 31a to 31c based on the coil information, and the curved rod which is matched to the cylindrical shape of the winding die 30 about the winding start of the metal sheet 2 to the winding die 30 It applies before winding up to the winding die 30. Therefore, even when the torque of the motor 16 c for the winding die 30 is relatively small, the metal sheet 2 is wound together with the insulating sheet 3 in close contact with the outer peripheral surface of the winding die 30.
  • control device 20 can calculate or correct the radius of curvature according to the thickness dimension of the metal sheet 2 or the like, and the integrated amount of the winding amount to the winding die 30, that is, the feed amount of the metal sheet 2 Based on the above, control is performed to adjust the positions of the forming rolls 31a to 31c. As a result, the curvature radius of the metal sheet 2 becomes larger (curvature becomes smaller) as the winding amount of the metal sheet 2 to be lap-wound on the winding die 30 via the insulating sheet 3 increases. Bending is performed by the rolls 31a to 31c. As a result, the cylindrical coil (see FIG. 5) wound in multiple layers does not have a gap between the layers, and has high dimensional accuracy and excellent short circuit mechanical force.
  • the bending device 31 has a curvature of the winding die 30 with respect to the metal sheet 2 or a curvature of the metal sheet 2 wound on the winding die 30 in an overlapping manner. It is configured to form a curved ridge corresponding to. According to this, it is possible to apply, to the metal sheet 2, a bending wedge corresponding to the winding amount to the winding die 30 before winding to the winding die 30, and for the cylindrical coil, the spring back Can be reliably eliminated, and dimensional accuracy can be enhanced. In addition, regardless of the rigidity of the metal sheet 2, the metal sheet 2 can be accurately wound around the winding die to prevent deviation, and the first embodiment can be made excellent in manufacturing efficiency and quality, etc. It produces the same effect as the form.
  • the bending device 31 of the second embodiment may be configured to have a function as a feeder as described above, or a feeder similar to the feeder 14 of the first embodiment may be placed near the entrance side of the bending device 31. It may be arranged.

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Coil Winding Methods And Apparatuses (AREA)
  • Wire Processing (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Winding, Rewinding, Material Storage Devices (AREA)

Abstract

A coil fabrication device according to the present embodiment comprises: a bending means for carrying out a bending work upon a metal sheet which is sent from a feeder, prior to rolling upon a former; and a control means for, with respect to the metal sheet, controlling the bending work of the bending means on the basis of the degree of sending the metal sheet from the feeder, such that the shape of the initial roll upon the former conforms to the outer circumference shape of the former, and thereafter, that the shape conforms to the outer circumference shape of the metal sheet which is rolled in overlapping layers upon said former.

Description

コイル及びその製造装置、並びにコイルの製造方法Coil, apparatus for manufacturing the same, and method for manufacturing coil
　本発明の実施形態は、コイル及びその製造装置、並びにコイルの製造方法に関する。 Embodiments of the present invention relate to a coil, an apparatus for manufacturing the same, and a method for manufacturing the coil.
　従来より、電力用や産業用の静止型誘導機器にあって、例えば変圧器のコイルでは、導体として帯状をなす金属シートを巻型の周りに巻装した構成のものが供されている。この種のコイルは、その仕様に応じて、角筒状や円筒状の巻型が使用される。また、金属シートは、例えば絶縁材料からなる絶縁シートと共に巻型に対して多層に巻回され、その層のうち任意の層に冷却用ダクトが配設される。 2. Description of the Related Art Conventionally, in stationary induction devices for electric power and industrial use, for example, in coils of transformers, a structure in which a band-like metal sheet as a conductor is wound around a winding form is provided. According to the specification, this type of coil uses a rectangular cylindrical or cylindrical winding type. Further, the metal sheet is wound in multiple layers around the winding mold together with an insulating sheet made of, for example, an insulating material, and a cooling duct is disposed in any of the layers.
　前記コイルは、金属シートを巻型に対し密着させるように巻き付ける等して、寸法精度を高めることが望ましい。しかしながら、金属シートの剛性如何によっては、巻型の巻き取りトルクを高めても、スプリングバックによる各層間の隙間が不可避的に発生する。このため、巻き取り後のコイルにおける巻き膨れ（寸法精度の低下）が生じるだけでなく、巻き取り中においても、金属シートに幅方向のずれが生じることとなる。この場合、当該ずれを修正するため、一旦巻き取りを停止してアンコイル側（材料供給側）で所謂蛇行調整を行わなければならず、作業負担となっていた。 It is desirable to increase dimensional accuracy by winding the metal sheet so as to be in close contact with the winding die. However, depending on the rigidity of the metal sheet, even if the winding torque of the winding form is increased, gaps between the layers due to spring back are inevitably generated. For this reason, not only winding swelling (reduction in dimensional accuracy) occurs in the coil after winding, but also deviation in the width direction occurs in the metal sheet during winding. In this case, in order to correct the deviation, it is necessary to stop the winding once and perform so-called meandering adjustment on the uncoil side (the material supply side), which is an operation load.
特開２０００－２１６６９号公報Japanese Patent Laid-Open No. 2000-21669
　そこで、寸法精度を極力高めることができると共に、製造効率性と品質に優れたコイル及びその製造装置、並びにコイルの製造方法を提供することである。 Accordingly, it is an object of the present invention to provide a coil which can improve the dimensional accuracy as much as possible and which is excellent in manufacturing efficiency and quality, a manufacturing apparatus therefor, and a method of manufacturing the coil.
　本実施形態のコイルの製造装置は、帯状の金属シートを巻回した巻回体から当該金属シートを繰り出す繰出手段と、前記繰出手段から繰り出した金属シートを回転しながら巻き取る巻型とを備えたものであり、前記繰出手段と前記巻型との間に設けられ、前記繰出手段により繰り出した金属シートを前記巻型側へ送るフィーダと、前記フィーダにより送られる金属シートに対して、前記巻型へ巻き取る前に曲げ加工を行う曲げ手段と、前記金属シートについて、前記巻型に対する巻き初めを当該巻型の外周形状に合わせた形状とし、以後、その巻型に重ね巻きされる金属シートの外周形状に合わせた形状となるよう、前記フィーダによる前記金属シートの送り量に基づき前記曲げ手段の曲げ加工を制御する制御手段とを備え、前記制御手段により前記曲げ加工を制御することで、前記巻型における金属シートの巻き取り量に応じた曲げ癖を、当該巻型への巻き取り前に付与する構成としたことを特徴とする。 The coil manufacturing apparatus of the present embodiment includes a feeding means for feeding the metal sheet from a wound body in which a band-like metal sheet is wound, and a winding type for winding and winding the metal sheet fed from the feeding means. And a feeder provided between the feeding means and the winding form for feeding the metal sheet fed out by the feeding means to the winding form, and the winding of the metal sheet sent by the feeder. Bending means that performs bending before winding into a mold, and the metal sheet, the start of winding on the winding mold has a shape according to the outer peripheral shape of the winding mold, and thereafter, the metal sheet is lap wound on the winding mold Control means for controlling the bending process of the bending means based on the feed amount of the metal sheet by the feeder so that the shape conforms to the outer peripheral shape of By controlling the more the bending, the winding amount curl depending on the metal sheet in the wound-type, characterized by being configured to impart the winding prior to the former.
第１実施形態を示すもので、コイルの製造装置の全体構成を説明するための概念図1, showing a first embodiment, is a conceptual diagram for explaining the overall configuration of a coil manufacturing apparatus. 電気的構成を示すブロック図Block diagram showing the electrical configuration コイルの構造を模式的に示す斜視図The perspective view which shows the structure of a coil typically 他のコイルの構造を模式的に示すもので、（ａ）は巻型の軸線方向から見て八角形をなすコイルの側面図、（ｂ）～（ｄ）は各種形態の冷却用ダクトを備えたコイルを示す（ａ）相当図The structure of another coil is schematically shown, and (a) is a side view of an octagonal coil when viewed from the axial direction of the winding form, (b) to (d) are provided with cooling ducts of various forms. (A) equivalent view showing the coil 第２実施形態を示す図１相当図1 equivalent figure which shows 2nd Embodiment
　図面中、１，１０１～１０４はコイル、２は金属シート、１１は巻回体、１２は繰出手段、１３はレベラー、１４はフィーダ、１６，３０は巻型、１５，３１は曲げ手段、２０は制御手段を示す。 In the drawings, reference numerals 1, 101 to 104 denote coils, 2 denotes a metal sheet, 11 denotes a wound body, 12 denotes a feeding means, 13 denotes a leveler, 14 denotes a feeder, 16, 30 denotes a winding type, 15, 31 denotes bending means, 20 Indicates a control means.
　＜第１実施形態＞
　以下、変圧器に用いられるコイルに適用した第１実施形態について、図１から図４を参照して説明する。 First Embodiment
Hereinafter, a first embodiment applied to a coil used for a transformer will be described with reference to FIGS. 1 to 4.
　図３に示すように、製造されるコイル１は、帯状をなす金属シート２と、同じく帯状をなす絶縁シート３とを巻型（図１の符号１６参照）に対して多層に巻回してなり、全体として例えば四角筒状をなす。金属シート２は、例えばアルミニウムからなる金属製の薄板材であり、絶縁シート３は、例えば絶縁性を有する断間紙である。コイル１は、図３中、符号Ｗで示す金属シート２の幅方向にずれがなく、多層に巻回された当該層間に隙間が生じないように形成されている。なお、金属シート２は、銅などの他の金属材料から形成してもよい。 As shown in FIG. 3, the coil 1 manufactured is formed by winding a metal sheet 2 in the form of a strip and an insulating sheet 3 in the form of the strip in the form of multiple layers around a winding form (see reference numeral 16 in FIG. 1). For example, a square tube shape is formed as a whole. The metal sheet 2 is a thin metal plate made of, for example, aluminum, and the insulating sheet 3 is, for example, an insulating sheet. The coil 1 is formed so that there is no deviation in the width direction of the metal sheet 2 indicated by reference numeral W in FIG. 3 and no gap is generated between the layers wound in multiple layers. The metal sheet 2 may be formed of another metal material such as copper.
　図１に示すコイル１の製造装置において、符号１１は金属シート２を予めフープ状に巻回した巻回体、符号１２は金属シート２を繰出すアンコイラ、符号１３は金属シート２の巻き癖を矯正するレベラー、符号１４は金属シート２を間欠送りするフィーダ、符号１５は金属シート２に対する曲げ手段としての曲げ装置である。 In the apparatus for manufacturing the coil 1 shown in FIG. 1, reference numeral 11 denotes a wound body in which a metal sheet 2 is wound in advance in a hoop shape, reference numeral 12 denotes an uncoiler for feeding the metal sheet 2, and reference numeral 13 denotes a winding of the metal sheet 2. Reference numeral 14 denotes a leveler for correcting, a feeder for intermittently feeding the metal sheet 2, and reference numeral 15 denotes a bending device as bending means for the metal sheet 2.
　即ち、巻回体１１は、予めフープ状に巻回されたフープ材としての金属シート２であり、アンコイラ１２の装着部１２ａに装着される。詳しい図示は省略するが、アンコイラ１２は、巻回体１１を装着部１２ａにて回転可能に支持し、巻回体１１の巻回方向とは反対方向の回転によって、金属シート２を繰り出す繰出手段として構成されている。 That is, the wound body 11 is the metal sheet 2 as a hoop material wound in a hoop shape in advance, and is mounted to the mounting portion 12 a of the uncoiler 12. Although not illustrated in detail, the uncoiler 12 rotatably supports the wound body 11 at the mounting portion 12a, and the feeding means for drawing out the metal sheet 2 by the rotation of the wound body 11 in the direction opposite to the winding direction. Is configured as.
　前記レベラー１３は、アンコイラ１２からの繰り出し方向の側に設けられ、図１に示すように千鳥状に配置された複数のワークロール１３ａ，１３ｂ，１３ｃを備える。繰り出された金属シート２における巻き癖は、これら上下のワークロール群１３ａ～１３ｃ間に通されることで矯正される。 The leveler 13 includes a plurality of work rolls 13a, 13b, and 13c which are provided on the side of the unwinding direction from the uncoiler 12 and are arranged in a zigzag as shown in FIG. The curl in the fed-out metal sheet 2 is corrected by being passed between the upper and lower work roll groups 13a to 13c.
　前記フィーダ１４は、レベラー１３で巻き癖が除去された金属シート２を、曲げ装置１５に向けて送りと停止とを繰り返す間欠送り動作を行う。詳細には、フィーダ１４は例えば、金属シート２を挟み付ける一対のロール１４ａ，１４ｂ、及び当該ロール１４ａ，１４ｂを駆動するためのモータ１４ｃ（図２参照）を備える。モータ１４ｃは、例えばサーボモータで構成されると共に、その回転量を検出するエンコーダ１４ｄ（図２参照）が付設され、フィードバック制御される。フィーダ１４による金属シート２の送り量は、エンコーダ１４ｄの検出信号等に基づき、後述する制御装置２０により算出されるようになっている。また、フィーダ１４のロール１４ａ、１４ｂは、曲げ装置１５との間で曲げ癖の成形誤差が生じないよう、曲げ装置１５に対する搬送方向前側（曲げ装置１５の入側近傍位置）に近接配置されている。詳しい説明及び図示は省略するが、ロール１４ａ，１４ｂは、例えばその表面の材質（及び形状）について、ロール１４ａ，１４ｂと金属シート２との間の摩擦抵抗が大きい材料（表面形状）で構成されると共に、所定の加圧力（挟持力）に設定されることで搬送精度が高められている。 The feeder 14 performs an intermittent feeding operation of repeating feeding and stopping of the metal sheet 2 whose curl is removed by the leveler 13 toward the bending device 15. Specifically, the feeder 14 includes, for example, a pair of rolls 14a and 14b for holding the metal sheet 2 and a motor 14c (see FIG. 2) for driving the rolls 14a and 14b. The motor 14c is constituted by, for example, a servomotor, and an encoder 14d (see FIG. 2) for detecting the amount of rotation is attached and feedback-controlled. The feed amount of the metal sheet 2 by the feeder 14 is calculated by a control device 20 described later based on a detection signal of the encoder 14 d and the like. Further, the rolls 14a and 14b of the feeder 14 are disposed close to the front side in the conveying direction with respect to the bending device 15 (a position near the entrance side of the bending device 15) so that forming errors of the bending rod do not occur with the bending device 15. There is. Although detailed description and illustration are omitted, the rolls 14a and 14b are made of, for example, a material (surface shape) having a large frictional resistance between the rolls 14a and 14b and the metal sheet 2 with respect to the material (and shape) of the surface thereof. By setting the pressure to a predetermined pressure (holding force), the conveyance accuracy is enhanced.
　前記曲げ装置１５は、フィーダ１４と巻型１６との間に配置され、金属シート２に対して、巻型１６に巻き取る前に折り曲げ加工を行う。曲げ装置１５は、曲げ型１７ａと、この曲げ型１７ａに沿って金属シート２を所定角度に塑性変形するように折り曲げる押え機構１７ｂとを備える。曲げ型１７ａは、巻型１６の外周形状或は製造するコイル１形状に合わせて種々のものが用意され、押え機構１７ｂは、金属シート２の板厚方向から当接する構成にある。これら曲げ型１７ａと押え機構１７ｂとの間での相対的な進退動作により、コイル１の金属シート２は、その幅方向（図１の紙面に対する垂直方向）から見て、例えば９０度に折曲形成される。こうして、曲げ装置１５は、巻型１６の角（かど）或は当該巻型１６に重ね巻きされる金属シート２の角に対応した、幅方向に延びる折目（折り曲げ癖）を形成する。なお、曲げ装置１５は、図４のコイル１０１～１０４の場合、金属シート２に対して４５度の折り曲げ癖を形成すると共に、コイル１０３，１０４におけるダクト１８の形状寸法に応じて、金属シート２の層間に隙間が生じないように折り曲げ癖を形成する。 The bending device 15 is disposed between the feeder 14 and the winding die 16 and performs bending on the metal sheet 2 before winding it on the winding die 16. The bending device 15 includes a bending die 17a and a pressing mechanism 17b which bends the metal sheet 2 so as to plastically deform the metal sheet 2 at a predetermined angle along the bending die 17a. Various bending dies 17a are prepared according to the outer peripheral shape of the winding die 16 or the shape of the coil 1 to be manufactured, and the pressing mechanism 17b is in contact with the metal sheet 2 in the thickness direction of the metal sheet 2. Due to the relative advancing and retracting motion between the bending die 17a and the pressing mechanism 17b, the metal sheet 2 of the coil 1 is bent at, for example, 90 degrees when viewed from the width direction (vertical direction to the paper of FIG. 1). It is formed. Thus, the bending device 15 forms a widthwise extending fold (folding crease) corresponding to the corner of the former 16 or the corner of the metal sheet 2 wound on the latter. In the case of the coils 101 to 104 in FIG. 4, the bending device 15 forms a bending wedge at 45 degrees with respect to the metal sheet 2, and the metal sheet 2 according to the shape and size of the duct 18 in the coils 103 and 104. Form a fold weir so that there is no gap between the two layers.
　前記巻型１６は、その回転軸１６ａの周りに回転しながら金属シート２と絶縁シート３とを巻き取る。巻型１６は、コイル１の形状やサイズ（図３で縦方向及び横方向の寸法や、金属シート２の幅寸法Ｗなど）に応じて、種々のものが用意されている。例えば、図１に示す巻型１６は、その外周形状が回転軸１６ａの軸線方向（同図の紙面に対する垂直方向）から見て四角形状をなす四角筒状のものである。この他、図示は省略するが、図４に示す各コイル１０１～１０４の巻型は、その外周形状が回転軸１６ａの軸線方向から見て八角形状をなす八角筒状のものである。巻型１６の回転軸１６ａは、駆動手段としてのモータ１６ｃ（図２参照）により回転駆動される。このモータ１６ｃの駆動に伴い、金属シート２及び絶縁シート３が巻型１６に対して同時に巻き付けられることで、多層に巻回される。 The winding form 16 winds the metal sheet 2 and the insulating sheet 3 while rotating around the rotation axis 16a. Various types of winding dies 16 are prepared according to the shape and size of the coil 1 (the dimensions in the longitudinal direction and the lateral direction, the width dimension W of the metal sheet 2 in FIG. 3, etc.). For example, the winding die 16 shown in FIG. 1 has a square cylindrical shape whose outer peripheral shape is square when viewed from the axial direction of the rotation shaft 16a (the direction perpendicular to the sheet of the drawing). In addition, although not shown, the winding form of each coil 101 to 104 shown in FIG. 4 is an octagonal cylinder whose outer peripheral shape is octagonal when viewed from the axial direction of the rotary shaft 16a. The rotating shaft 16a of the winding form 16 is rotationally driven by a motor 16c (see FIG. 2) as a driving means. As the motor 16c is driven, the metal sheet 2 and the insulating sheet 3 are simultaneously wound around the winding die 16 to be wound in multiple layers.
　前記冷却用のダクトは、例えば八角筒状のコイル１０２～１０４を製造する場合に、多層に巻回された金属シート２（絶縁シート３）における所定の層に配設される。具体的には例えば、図４（ｃ）、（ｄ）に示すコイル１０３，１０４のダクト１８は、絶縁材料からなる棒状のダクトピース１８ａと、取付部材としての台紙１８ｂとを備えている。ダクトピース１８ａは、台紙１８ｂに対し所定間隔で複数並べて固定配置され、一体化した構成にある。このダクト１８は、金属シート２及び絶縁シート３の巻型１６への巻回の途中で、コイル１０３，１０４毎に予め設定されたダクト挿入層Ｉに、台紙１８ｂにおける接着剤や粘着剤などの固定手段により固定される。八角筒状をなすコイル１０３の場合、図４（ｃ）で上辺部、下辺部及び両側辺部に、ダクト挿入層Ｉにおけるダクト１８用の配設スペースが形成される。一方、コイル１０４の場合、図４（ｄ）で上辺部及び下辺部にダクト挿入層Ｉにおけるダクト１８用の配設スペースが形成される。 The duct for cooling is disposed, for example, in a predetermined layer of the metal sheet 2 (insulation sheet 3) wound in multiple layers when manufacturing octagonal cylindrical coils 102 to 104. Specifically, for example, the ducts 18 of the coils 103 and 104 shown in FIGS. 4C and 4D include a rod-shaped duct piece 18a made of an insulating material and a mount 18b as a mounting member. The duct pieces 18a are arranged in a fixed manner at predetermined intervals with respect to the backing sheet 18b, and have an integrated configuration. During the winding of the metal sheet 2 and the insulating sheet 3 to the winding die 16, the duct 18 is provided on a duct insertion layer I preset for each of the coils 103 and 104, such as an adhesive or adhesive on the mount 18b. It is fixed by the fixing means. In the case of the coil 103 having an octagonal cylindrical shape, an arrangement space for the duct 18 in the duct insertion layer I is formed in the upper side portion, the lower side portion and both side portions in FIG. On the other hand, in the case of the coil 104, an arrangement space for the duct 18 in the duct insertion layer I is formed at the upper side and the lower side in FIG. 4 (d).
　前述のように、ダクト１８用の配設スペースは、ダクト１８の形状寸法に応じて、金属シート２とダクト１８が密接するように形成されるため、金属シート２の放熱効果が高められる。また、ダクト挿入層Ｉにおいてダクト１８を設けない部分は、隙間が生じないよう曲げ装置１５により前記折り曲げ癖をつけてある。このため、ダクト１８用の配設スペースを設けても、当該スペース（特に角部分）がウィークポイントとなるのを防止することができ、コイル１０３，１０４全体として、短絡機械力つまり短絡電流が流れたときに作用する機械力等に優れたものとなる。 As described above, the arrangement space for the duct 18 is formed such that the metal sheet 2 and the duct 18 are in close contact with each other in accordance with the shape and size of the duct 18, so the heat radiation effect of the metal sheet 2 is enhanced. Further, in the duct insertion layer I, the portion not provided with the duct 18 is provided with the bending crease by the bending device 15 so that no gap is generated. For this reason, even if the arrangement space for the duct 18 is provided, it is possible to prevent the space (particularly, the corner portion) from becoming a weak point, and short circuit mechanical force, that is, short circuit current flows as the coils 103 and 104 as a whole. It is excellent in the mechanical force etc. which act when it
　図４（ｂ）に示すコイル１０２のダクト１９は、例えば波形に形成された波形ダクトである。このコイル１０２の場合、その全周にわたってダクト挿入層Ｉにおけるダクト１９用の配設スペースが形成される。ダクト１９用の配設スペースも、ダクト１９の形状寸法に応じて形成されるため、上記のように放熱効果が高く且つ機械的特性に優れたものとすることができる。なお、コイル１０２に対し波形のダクト１９に代えて、棒状のダクトピース１８ａを有するダクト１８を配設するなど、ダクトの形状や配置形態は適宜変更してもよい。また、コイル全体の形状としては、図３のコイル１のように四角筒状とし、或は図４のコイル１０１～１０４のように八角筒状とするなど適宜変更が可能である。 The duct 19 of the coil 102 shown in FIG. 4B is, for example, a corrugated duct formed in a corrugated shape. In the case of this coil 102, an arrangement space for the duct 19 in the duct insertion layer I is formed over the entire circumference thereof. Since the arrangement space for the duct 19 is also formed in accordance with the shape and size of the duct 19, as described above, the heat radiation effect can be high and the mechanical characteristics can be excellent. The shape and arrangement of the ducts may be changed as appropriate, such as disposing a duct 18 having a rod-shaped duct piece 18a instead of the corrugated duct 19 for the coil 102. Further, the shape of the entire coil may be changed as appropriate, for example, a square cylindrical shape as in the coil 1 of FIG. 3 or an octagonal cylindrical shape as in the coils 101 to 104 of FIG.
　図２は、コイル１，１０１～１０４の製造に係る制御系の構成を示すブロック図である。制御装置２０は、マイクロコンピュータを主体に構成されており、内部にＣＰＵ、並びにＲＯＭ、ＲＡＭ、不揮発性メモリを含む記憶部２１を有する制御手段である。制御装置２０には、前記エンコーダ１４ｄや、操作パネルのキースイッチ（何れも図示せず）からの各種操作信号を入力するための操作入力部２２が接続されている。また、制御装置２０には、巻型１６の近傍に位置させて金属シート２の巻取り状態を検出するように設けた検出センサを含む、各種検出センサ２３が接続されている。例えば、検出センサ２３として、金属シート２における巻き初めの端部を検出するためのシート検出手段や、金属シート２の厚さ寸法を検出する板厚検出手段を設けるようにしてもよい。更に、制御装置２０には、フィーダ１４用のモータ１４ｃ、押え機構１７ｂ、巻型１６用のモータ１６ｃを夫々駆動する駆動回路２４，２５，２６が接続されている。 FIG. 2 is a block diagram showing a configuration of a control system related to the manufacture of the coils 1, 101 to 104. As shown in FIG. The control device 20 is mainly configured of a microcomputer, and is a control unit having a storage unit 21 including a CPU, a ROM, a RAM, and a non-volatile memory. The control device 20 is connected to the encoder 14d and an operation input unit 22 for inputting various operation signals from key switches (not shown) of the operation panel. The control device 20 is also connected to various detection sensors 23 including a detection sensor provided near the winding die 16 to detect the winding state of the metal sheet 2. For example, as the detection sensor 23, a sheet detection unit for detecting an end portion of the metal sheet 2 at the beginning of winding, or a plate thickness detection unit for detecting a thickness dimension of the metal sheet 2 may be provided. Furthermore, drive circuits 24, 25 and 26 for driving the motor 14c for the feeder 14, the pressing mechanism 17b, and the motor 16c for the winding die 16 are connected to the control device 20.
　前記記憶部２１には、コイル１，１０１～１０４に関するコイル情報、ダクト１８，１９に関するダクト情報などが予め記憶されている。コイル情報は、例えばコイル１の場合、巻型１６に対応付けられた形状や各寸法（図３中、縦方向の長辺寸法及び横方向の短辺寸法）の他、金属シート２の厚さ寸法などの情報を含み、コイル１，１０１～１０４毎に規定されている。ダクト情報は、ダクト１８，１９の各寸法の他、各コイル１０２～１０４における前記配設スペースの位置情報を含み、コイル情報に関連付けて規定されている。これらコイル情報及びダクト情報は、以下の作用説明で述べるように作業者による操作入力部２２の操作に基づき設定するようにしてもよいし、検出センサ２３から厚さ寸法を取得するようにしてもよい。そして、制御装置２０は、上記した情報に基づいて、モータ１４ｃ，１６ｃ、押え機構１７ｂ等の各種アクチュエータを制御し、巻型１６へ金属シート２の巻き取り動作を自動で実行させるようになっている。 In the storage unit 21, coil information on the coils 1, 101 to 104, duct information on the ducts 18, 19 and the like are stored in advance. The coil information is, for example, in the case of the coil 1, the thickness of the metal sheet 2 in addition to the shape and dimensions (long side dimension in the vertical direction and short side dimension in the horizontal direction in FIG. 3) It includes information such as dimensions and is defined for each coil 1, 101 to 104. The duct information includes positional information of the installation space in each of the coils 102 to 104 in addition to the dimensions of the ducts 18 and 19, and is defined in association with the coil information. The coil information and the duct information may be set based on the operation of the operation input unit 22 by the operator as described in the following description of the operation, or even if the thickness dimension is acquired from the detection sensor 23 Good. Then, the control device 20 controls various actuators such as the motors 14c and 16c and the pressing mechanism 17b based on the above information, and causes the winding die 16 to automatically execute the winding operation of the metal sheet 2 There is.
　次に上記構成の作用について説明する。
　前記金属シート２の巻回体１１は、予めアンコイラ１２の装着部１２ａに装着され、巻回体１１の巻き終わり端側を繰り出して、レベラー１３、フィーダ１４及び曲げ装置１５を経由し、巻型１６側へ送るようにセットされるものとする。なお、巻回体１１の巻き終わり端部は、巻型１６への巻き初め端部となる。また、絶縁シート３の巻回体１１´は、巻回体１１とは別の装着部１２ａ´に装着され、その繰出手段１２´から巻型１６側へ送るようにセットされる。 Next, the operation of the above configuration will be described.
The wound body 11 of the metal sheet 2 is attached to the mounting portion 12a of the uncoiler 12 in advance, and the winding end end side of the wound body 11 is fed out to pass through the leveler 13, the feeder 14 and the bending device 15 It shall be set to send to the 16 side. In addition, the winding end end of the winding body 11 is the winding start end to the winding die 16. The wound body 11 'of the insulating sheet 3 is mounted on a mounting portion 12a' different from the wound body 11, and is set to be fed from the feeding means 12 'to the winding die 16 side.
　作業者は、操作入力部２２を操作して、製造するコイル１，１０１～１０４の種別を選定し、或は、コイル情報及びダクト情報を設定する。そして、操作入力部２２のスタートスイッチが操作されると、巻回体１１から金属シート２が繰り出されると共に、フィーダ１４による間欠的な送り動作が行われる。この場合、巻回体１１から繰り出される金属シート２は、レベラー１３にて上下のワークロール群１３ａ～１３ｃ間に通されることで、内部ひずみが除去され、巻き癖が矯正されて平坦となる。またこの場合、制御装置２０は、フィーダ１４用のモータ１４ｃについて、エンコーダ１４ｄの検出信号に基づき金属シート２の送り量を算出し、前記コイル情報に基づいて、巻型１６の角、或は当該巻型１６に重ね巻きされる金属シート２の角に対応した折り曲げ癖を形成するように間欠的に駆動させる。 The operator operates the operation input unit 22 to select the type of the coils 1, 101 to 104 to be manufactured, or set the coil information and the duct information. Then, when the start switch of the operation input unit 22 is operated, the metal sheet 2 is drawn out from the wound body 11 and the intermittent feeding operation by the feeder 14 is performed. In this case, the metal sheet 2 fed out from the wound body 11 is passed between the upper and lower work roll groups 13a to 13c by the leveler 13 so that the internal strain is removed and the curl is corrected to be flat. . Also, in this case, the control device 20 calculates the feed amount of the metal sheet 2 based on the detection signal of the encoder 14d for the motor 14c for the feeder 14, and based on the coil information, It is intermittently driven so as to form a bending rod corresponding to the corner of the metal sheet 2 to be lap-wound on the winding die 16.
　この送り行程における送り量について、具体的な例を仮定して詳述する。例えば図３のコイル１を製造するに際し同図中、Ｐ０で示す巻型１６への巻き初め端部が、巻型１６の角に固定されるものとする。また、図１に示すように、前記軸線方向から見て四角形状をなす巻型１６は、その短辺寸法をＭ１、長辺寸法をＭ２とする。この場合、制御装置２０は、コイル情報に基づいて、巻型１６への巻き初め端部Ｐ０からの送り量Ｌ１が短辺寸法と同じＭ１となるようフィーダ１４用のモータ１４ｃへ駆動信号を出力する。その後、制御装置２０は、モータ１４ｃが停止した状態で曲げ型１７ａ側へ、押え機構１７ｂを進退動作させる（曲げ行程）。これにより、金属シート２には、巻き初め端部Ｐ０からＭ１分、離間したＰ１の位置に９０度の折り曲げ癖たる折曲部が形成される（図３参照）。 The feed amount in this feed stroke will be described in detail on the assumption of a specific example. For example, when manufacturing the coil 1 of FIG. 3, it is assumed that the winding start end to the winding form 16 shown by P0 in the same figure is fixed to the corner of the winding form 16. Further, as shown in FIG. 1, the winding die 16 having a rectangular shape when viewed from the axial direction has a short side dimension of M1 and a long side dimension of M2. In this case, the control unit 20 based on the coil information, a drive signal to the motor 14c for the feeder 14 to feed amount L 1 are the same M1 and short side dimension from the winding beginning end P0 of the former 16 Output. Thereafter, the control device 20 moves the pressing mechanism 17b forward and backward toward the bending die 17a in a state where the motor 14c is stopped (bending stroke). As a result, the metal sheet 2 is formed with a 90-degree bent portion at a position of P1 separated from the winding start end P0 by M1 minutes (see FIG. 3).
　また、制御装置２０は、２回目の送り量Ｌ２について巻型１６の長辺寸法と同じＭ２となるようモータ１４ｃを駆動した後、押え機構１７ｂを進退動作させる。これにより、金属シート２には、折曲部Ｐ１からＭ２分、離間したＰ２の位置に９０度の折曲部が形成される。こうして、巻型１６に接する（或は絶縁シート３を介して密接する）金属シート２の巻き初めは、フィーダ１４による送り量Ｌ１，Ｌ２，Ｌ３が、巻型１６の角に夫々対応したＭ１，Ｍ２，Ｍ１に設定され、そのモータ１４ｃの駆動が停止される度に曲げ加工が行われることで、塑性変形した折曲部Ｐ１，Ｐ２，Ｐ３が形成される。 Further, the control device 20 drives the motor 14c so that the second side feed amount L2 becomes M2 equal to the long side dimension of the winding die 16, and then moves the pressing mechanism 17b forward and backward. Thereby, a 90 ° bent portion is formed on the metal sheet 2 at a position P2 separated from the bent portion P1 by M2. Thus, at the beginning of winding of the metal sheet 2 in contact with the form 16 (or in close contact with the insulating sheet 3), the feed amounts L 1 , L 2 and L 3 by the feeder 14 correspond to the corners of the form 16 respectively. The bending portions are set to M1, M2 and M1 and bending is performed each time the driving of the motor 14c is stopped, thereby forming the plastically deformed bent portions P1, P2 and P3.
　例えば、巻型１６用のモータ１６ｃは、フィーダ１４用のモータ１４ｃと同期（同調）するように駆動される。このため、巻型１６用のモータ１６ｃのトルクが比較的小さい場合でも、金属シート２は、巻型１６の外周面に密接するようにして絶縁シート３と共に巻き取られ、９０度の折曲部Ｐ１～Ｐ３においても巻型１６の角との間に隙間が生じることはない。なお、制御装置２０は、折曲部Ｐ３形成後の送り量Ｌ４について、前記コイル情報に基づき、金属シート２の板厚の分を加算した位置（Ｌ４＝Ｍ２＋板厚）に折曲部が形成されるようにモータ１４ｃを駆動する。 For example, the motor 16 c for the form 16 is driven to synchronize with the motor 14 c for the feeder 14. Therefore, even when the torque of the motor 16c for the winding form 16 is relatively small, the metal sheet 2 is wound along with the insulating sheet 3 so as to be in close contact with the outer peripheral surface of the winding form 16 and a 90 ° bent portion Also in P1 to P3, no gap is generated between it and the corner of the mold 16. The control device 20, for feeding amount L 4 after bent portion P3 is formed, based on said coil information, the bent portion at a position obtained by adding the amount of plate thickness of the metal sheet 2 (L 4 = M2 + thickness) The motor 14c is driven such that
　以後、制御装置２０は、巻型１６に絶縁シート３を介して重ね巻きされる金属シート２の外周形状に合わせた形状となるよう、フィーダ１４による金属シート２の送り量Ｌ５，Ｌ６，…，ＬＮ，ＬＮ＋１，…を設定する（図１参照）。即ち、制御装置２０は、上記した巻型１６に係る寸法Ｍ１，Ｍ２や金属シート２（及び絶縁シート３）の厚さ寸法などのコイル情報に基づいて、既に巻き取られたシート材２，３の厚みを見越した送り量Ｌ５～を演算する。そして、送り量Ｌ５～に応じて順次曲げ装置１５による曲げ加工が行われることで、金属シート２は、巻型１６における巻き取り量に応じた折曲部が、当該巻型１６への巻き取り前に付与される。この結果、図３に示すように、多層に巻回されたコイル１は、その層間に隙間が発生することはなく、寸法精度が高く且つ短絡機械力に優れたものとなる。 Thereafter, the control device 20 feeds the feed amounts L 5 , L 6 , L 6 of the metal sheet 2 by the feeder 14 so that the shape conforms to the outer peripheral shape of the metal sheet 2 to be wound in an overlapping manner on the winding die 16 via the insulating sheet 3. , L N , L N + 1 ,... Are set (see FIG. 1). That is, the control device 20 takes the sheet materials 2 and 3 already taken up based on the coil information such as the dimensions M1 and M2 of the winding die 16 and the thickness of the metal sheet 2 (and the insulation sheet 3). The feed amount L 5 ~ in anticipation of the thickness of is calculated. Then, bending is sequentially performed by the bending device 15 in accordance with the feed amount L 5 and so that the metal sheet 2 is wound on the winding die 16 at the bending portion according to the winding amount in the winding die 16. It is given before taking it. As a result, as shown in FIG. 3, the coil 1 wound in multiple layers does not have a gap between the layers, and has high dimensional accuracy and excellent short circuit mechanical force.
　他方、図４に示すコイル１０１～１０４の製造にあっては、上記したコイル１と異なり、四角筒状の巻型１６に代えて八角筒状の巻型（図示略）が用いられる。また、図示は省略するが、例えば９０度の折曲部を形成するための曲げ型１７ａに代えて、４５度の折曲部を形成するための曲げ型が用いられる。 On the other hand, in the production of the coils 101 to 104 shown in FIG. 4, an octagonal cylindrical winding type (not shown) is used instead of the rectangular cylindrical winding type 16 unlike the coil 1 described above. Although not shown, for example, a bending die for forming a 45-degree bent portion is used in place of the bending die 17a for forming a 90-degree bending portion.
　更に、冷却用のダクトを有するコイル１０２～１０４の製造方法について、上記したコイル１と異なる点を、図４（ｄ）のコイル１０４を例に説明する。
　制御装置２０は、前記コイル情報及びダクト情報と、送り量の積算値とに基づいて、金属シート２における前記ダクト挿入層Ｉの被取付部Ｉａ，Ｉｂ（図４（ｄ）参照）の夫々が重ね巻きされる前にフィーダ１４の駆動を一旦停止する。この場合、予め用意した各ダクト１８を、夫々の被取付部Ｉａ，Ｉｂに手作業により取付け固定する（自動化してもよい）。このとき、金属シート２における被取付部Ｉａ，Ｉｂは、フィーダ１４及び曲げ装置１５よりも巻型１６側に位置し、４５度の折曲部を指標として識別することができ、各ダクト１８を正確に取付けることができる。 Further, with respect to a method of manufacturing the coils 102 to 104 having a cooling duct, points different from the above-described coil 1 will be described taking the coil 104 of FIG. 4D as an example.
Each of the attachment parts Ia and Ib (see FIG. 4D) of the duct insertion layer I in the metal sheet 2 controls the control device 20 based on the coil information, the duct information, and the integrated value of the feed amount. The driving of the feeder 14 is temporarily stopped before being wound in an overlapping manner. In this case, each duct 18 prepared in advance is attached and fixed to each of the attached parts Ia and Ib manually (it may be automated). At this time, the attached portions Ia and Ib in the metal sheet 2 are located closer to the winding die 16 than the feeder 14 and the bending device 15, and can identify the 45-degree bent portion as an index. It can be installed accurately.
　この後、制御装置２０によって、図４（ｄ）で上辺部及び下辺部にダクト１８用の配設スペースが形成されるように金属シート２の送り量が設定される。このため、当該折曲部は、ダクト１８の形状寸法に応じて、金属シート２とダクト１８が密接するように形成されるため、金属シート２の放熱効果が高められる。この結果、図４（ｄ）に示すように、多層に巻回されたコイル１０４は、ダクト１８用の配設スペースを除いて層間に隙間が発生することはなく、寸法精度が高く且つ短絡機械力に優れたものとなる。 Thereafter, the feed amount of the metal sheet 2 is set by the control device 20 so that the arrangement space for the duct 18 is formed in the upper side and the lower side in FIG. 4D. For this reason, since the said bending part is formed so that the metal sheet 2 and the duct 18 may closely contact according to the shape dimension of the duct 18, the heat dissipation effect of the metal sheet 2 is heightened. As a result, as shown in FIG. 4 (d), the coil 104 wound in multiple layers does not have a gap between the layers except for the installation space for the duct 18, and has high dimensional accuracy and a short circuit machine. It will be excellent in power.
　更には、上記した何れのコイル１，１０１～１０４の製造方法でも、金属シート２の板厚を含むコイル情報及びダクト情報並びに巻型における巻き取り量（巻型の大きさと送り量の積算値とから得られる巻回数）に基づき、制御装置２０によりフィーダ１４の送り量を演算した上で前記曲げ加工が行われるため、高精度の寸法出しを行うことができる。 Furthermore, coil information including the thickness of the metal sheet 2 and duct information, and the amount of winding in the winding type (the integrated value of the size of the winding type and the feed amount) Since the bending process is performed after the feed amount of the feeder 14 is calculated by the control device 20 based on the number of turns obtained from the above, dimensioning with high accuracy can be performed.
　以上のように本実施形態のコイル１，１０１～１０４の製造装置は、繰出手段により繰り出した金属シート２を巻型側へ送るフィーダ１４と、このフィーダ１４により送られる金属シート２に対して、巻型へ巻き取る前に曲げ加工を行う曲げ装置１５と、金属シート２について、巻型に対する巻き初めを当該巻型の外周形状に合わせた形状とし、以後、その巻型に重ね巻きされる金属シート２の外周形状に合わせた形状となるよう、フィーダ１４による金属シート２の送り量に基づき曲げ装置１５の曲げ加工を制御する制御装置２０とを備え、制御装置２０による曲げ加工の制御により、巻型における金属シート２の巻き取り量に応じた曲げ癖を、当該巻型への巻き取り前に付与する構成とした。 As described above, the manufacturing apparatus of the coils 1, 101 to 104 according to the present embodiment includes the feeder 14 for feeding the metal sheet 2 fed out by the feeding means to the winding die and the metal sheet 2 sent by the feeder 14 The bending device 15 which performs bending before winding into a winding die and the metal sheet 2 have a shape in which the winding start of the winding die is matched to the outer peripheral shape of the winding die, And a control device 20 for controlling bending of the bending device 15 based on the feed amount of the metal sheet 2 by the feeder 14 so that the shape conforms to the outer peripheral shape of the sheet 2. A bending weir in accordance with the winding amount of the metal sheet 2 in the winding die is applied before the winding in the winding die.
　この構成によれば、金属シート２に対し、巻型の外周形状及び当該巻型への巻き取り量に応じた曲げ癖を、当該巻型への巻き取り前に付与することができる。このため、巻き取り後のコイル１，１０１～１０４について、スプリングバックによる巻き膨れを確実に無くすことができ、寸法精度を高めることができる。この点、本実施形態と異なり、巻型側への金属シートの巻き取りを精度よく行えない場合、その巻き取り中の金属シートに、幅方向のずれが生じて巻き取りが中断されることがある。これに対し、上記構成によれば、金属シート２の厚みや剛性如何にかかわらず、巻型の巻き取りトルクが比較的小さくても、金属シート２を巻型に正確に巻き付けてずれを防止することができ、製造効率性と品質に優れたものとすることができる。 According to this configuration, it is possible to apply, to the metal sheet 2, the bending crease according to the outer peripheral shape of the winding die and the winding amount to the winding die before winding up to the winding die. For this reason, with respect to the coils 1, 101 to 104 after being wound up, it is possible to reliably eliminate the winding expansion due to the spring back, and to improve the dimensional accuracy. In this respect, unlike the present embodiment, when the metal sheet on the winding die side can not be wound with high accuracy, the metal sheet being wound may be shifted in the width direction and the winding may be interrupted. is there. On the other hand, according to the above configuration, regardless of the thickness and rigidity of the metal sheet 2, even if the winding torque of the winding mold is relatively small, the metal sheet 2 is accurately wound around the winding mold to prevent deviation. And can be excellent in manufacturing efficiency and quality.
　巻型の外周形状は、その回転軸１６ａの軸線方向から見て多角形をなし、曲げ装置１５は、金属シート２に対して、巻型の角、或は当該巻型に重ね巻きされる金属シート２の角に対応した折り曲げ癖を形成するように構成されている。これによれば、多角形をなすコイル１，１０１～１０４であっても、曲げ装置１５によって予め角部を塑性域まで確実に折り曲げることができる。従って、当該角部における層間の隙間を確実に無くすことができ、高精度の寸法出しを行うことができる。 The outer peripheral shape of the winding form is a polygon when viewed from the axial direction of the rotation shaft 16a, and the bending device 15 is a metal wound on the corner of the winding form or the winding form with respect to the metal sheet 2. It is configured to form a fold weir corresponding to the corner of the sheet 2. According to this, even in the case of polygonal coils 1, 101 to 104, the corner portion can be bent in advance to the plastic region by the bending device 15 in advance. Therefore, the gap between the layers at the corner can be surely eliminated, and dimensioning with high accuracy can be performed.
　特に、冷却用のダクト１８，１９を有するコイル１０２～１０４について、ダクト１８，１９の形状寸法に応じて、金属シート２とダクト１８，１９が密接するように形成されるため、金属シート２の放熱効果を向上させることができると共に、短絡機械力等に優れたものとすることができる。 In particular, in the coils 102 to 104 having the cooling ducts 18 and 19, the metal sheet 2 and the ducts 18 and 19 are formed to be in close contact with each other according to the shape and size of the ducts 18 and 19. While being able to improve a heat dissipation effect, it can be excellent in short circuit mechanical force etc.
　フィーダ１４及び曲げ装置１５は、製造装置において相互に近接する配置とした。これによれば、フィーダ１４及び曲げ装置１５間における金属シート２の撓み等に起因する成形誤差を極力無くすことができ、寸法精度を一層向上させることができる。 The feeder 14 and the bending device 15 are disposed close to each other in the manufacturing device. According to this, it is possible to minimize the forming error caused by the bending or the like of the metal sheet 2 between the feeder 14 and the bending device 15, and to further improve the dimensional accuracy.
　前記繰出手段とフィーダ１４との間に設けられ、繰出手段から繰り出された金属シート２の巻き癖を矯正するレベラー１３を備える。これによれば、レベラー１３によって、内部ひずみが除去され、巻き癖が矯正されて平坦とすることができ、より高精度のコイル１，１０１～１０４を安定して成形することができる。 The leveler 13 is provided between the feeding means and the feeder 14 and corrects the curl of the metal sheet 2 fed from the feeding means. According to this, the internal strain is removed by the leveler 13, and the curling can be corrected to be flat, and the coils 1, 101 to 104 with higher accuracy can be stably formed.
　＜第２実施形態＞
　図５は第２実施形態を示すものであり、既述の部分と同一部分には同一符号を付す等して説明を省略し、以下異なる点につき説明する。 Second Embodiment
FIG. 5 shows a second embodiment. The same reference numerals are given to the same parts as the parts described above, and the description thereof will be omitted.
　本第２実施形態の巻型３０は、その外周形状が回転軸１６ａの軸線方向から円環状をなす円筒状のものである。曲げ手段としての曲げ装置３１は、例えば複数の成形ロール３１ａ～３１ｃからなり、巻型３０の曲率、或は当該巻型３０に重ね巻きされる金属シート２の曲率に対応した湾曲癖を形成するように構成されている。 The winding die 30 of the second embodiment has a cylindrical shape whose outer peripheral shape is annular in the axial direction of the rotation shaft 16a. The bending device 31 as a bending means includes, for example, a plurality of forming rolls 31a to 31c, and forms a curved ridge corresponding to the curvature of the winding die 30 or the curvature of the metal sheet 2 wound on the winding die 30 in an overlapping manner. Is configured as.
　具体的には、記憶部２１には、金属シート２の送り量及び巻型３０の種類毎に対応付けた曲率半径のデータが、コイル情報として予め記憶されている。そして、制御装置２０は、前記曲率半径のデータに基づいて、図５に例示する成形ロール３１ａ～３１ｃの位置（例えば上下方向の位置）を、巻型３０の外形或は当該巻型３０に重ね巻きされた金属シート２の外形に合った形状に曲成するよう、送り量に連動して変更する。当該送り量は、曲げ装置３１に対する搬送方向前側に近接配置された前記フィーダ１４（図５において図示略）による連続送りとしてもよい。或は、成形ロール３１ａ～３１ｃの何れかを駆動するためのサーボモータ及びエンコーダ（何れも図示略）を付設し、成形ロール３１ａ～３１ｃについて、所定の加圧力で金属シート２を挟み付けて駆動するように構成することで、前記フィーダ１４と同様の機能を併せ持たせてもよい。 Specifically, data of the radius of curvature associated with the feed amount of the metal sheet 2 and the type of the winding die 30 is stored in advance in the storage unit 21 as coil information. Then, based on the data of the radius of curvature, the control device 20 superimposes the positions (for example, the positions in the vertical direction) of the forming rolls 31a to 31c illustrated in FIG. 5 on the outer shape of the winding die 30 or the winding die 30. The feed amount is changed in conjunction with the feed amount so as to be bent to a shape that conforms to the outer shape of the wound metal sheet 2. The feed amount may be continuous feed by the feeder 14 (not shown in FIG. 5) disposed close to the front side in the conveyance direction with respect to the bending device 31. Alternatively, a servomotor and an encoder (both not shown) for driving any of the forming rolls 31a to 31c are attached, and the metal sheet 2 is sandwiched and driven with a predetermined pressure on the forming rolls 31a to 31c. The same function as the above-mentioned feeder 14 may be given together by comprising.
　なお、図５において図示は省略するが、成形ロール３１ａ～３１ｃとアンコイラ１２との間に第１実施形態と同様にレベラーを配設し、予め内部ひずみを除去する構成としてもよい。 Although not shown in FIG. 5, a leveler may be disposed between the forming rolls 31a to 31c and the uncoiler 12 as in the first embodiment to remove internal strain in advance.
　上記構成において、巻回体１１から金属シート２が繰り出されると共に、フィーダ１４（或は成形ロール３１ａ～３１ｃ）による連続的な送り動作が行われる。この曲げ行程（及び送り行程）において、成形ロール３１ａ～３１ｃにより、金属シート２が塑性域で曲成されるため、金属シート２の内部ひずみを低減することができる。 In the above configuration, the metal sheet 2 is unwound from the wound body 11, and the continuous feeding operation by the feeder 14 (or the forming rolls 31a to 31c) is performed. In this bending process (and the feeding process), the metal sheet 2 is bent in the plastic region by the forming rolls 31a to 31c, so that the internal strain of the metal sheet 2 can be reduced.
　そして、制御装置２０は、前記コイル情報に基づく成形ロール３１ａ～３１ｃによる曲げ加工を制御し、巻型３０に対する金属シート２の巻き初めについて当該巻型３０の円筒形状に合わせた湾曲癖を、当該巻型３０へ巻き取る前に付与する。このため、巻型３０用のモータ１６ｃのトルクが比較的小さい場合でも、金属シート２は、巻型３０の外周面に密接するようにして絶縁シート３と共に巻き取られる。また、制御装置２０は、金属シート２の厚さ寸法等に応じて前記曲率半径を演算し或は補正することができ、巻型３０への巻き取り量つまり金属シート２の送り量の積算値に基づいて、成形ロール３１ａ～３１ｃの位置を調整する制御を行う。これにより、巻型３０に絶縁シート３を介して重ね巻きされる金属シート２の巻き取り量が増加することに伴い、金属シート２の曲率半径が大きくなる（曲率は小さくなる）ように、成形ロール３１ａ～３１ｃで曲げ加工が行われる。この結果、多層に巻回された円筒状のコイル（図５参照）は、その層間に隙間が発生することはなく、寸法精度が高く且つ短絡機械力に優れたものとなる。 Then, the control device 20 controls the bending process by the forming rolls 31a to 31c based on the coil information, and the curved rod which is matched to the cylindrical shape of the winding die 30 about the winding start of the metal sheet 2 to the winding die 30 It applies before winding up to the winding die 30. Therefore, even when the torque of the motor 16 c for the winding die 30 is relatively small, the metal sheet 2 is wound together with the insulating sheet 3 in close contact with the outer peripheral surface of the winding die 30. Further, the control device 20 can calculate or correct the radius of curvature according to the thickness dimension of the metal sheet 2 or the like, and the integrated amount of the winding amount to the winding die 30, that is, the feed amount of the metal sheet 2 Based on the above, control is performed to adjust the positions of the forming rolls 31a to 31c. As a result, the curvature radius of the metal sheet 2 becomes larger (curvature becomes smaller) as the winding amount of the metal sheet 2 to be lap-wound on the winding die 30 via the insulating sheet 3 increases. Bending is performed by the rolls 31a to 31c. As a result, the cylindrical coil (see FIG. 5) wound in multiple layers does not have a gap between the layers, and has high dimensional accuracy and excellent short circuit mechanical force.
　以上のように本第２実施形態のコイルの製造装置において、曲げ装置３１は、金属シート２に対して、巻型３０の曲率、或は当該巻型３０に重ね巻きされる金属シート２の曲率に対応した湾曲癖を形成するように構成されている。これによれば、金属シート２に対し、巻型３０への巻き取り量に応じた湾曲癖を、当該巻型３０への巻き取り前に付与することができ、円筒状のコイルについて、スプリングバックによる巻き膨れを確実に無くすことができ、寸法精度を高めることができる。また、金属シート２の剛性如何にかかわらず、金属シート２を巻型に正確に巻き付けてずれを防止することができ、製造効率性と品質に優れたものとすることができる等、第１実施形態と同様の効果を奏する。 As described above, in the coil manufacturing apparatus of the second embodiment, the bending device 31 has a curvature of the winding die 30 with respect to the metal sheet 2 or a curvature of the metal sheet 2 wound on the winding die 30 in an overlapping manner. It is configured to form a curved ridge corresponding to. According to this, it is possible to apply, to the metal sheet 2, a bending wedge corresponding to the winding amount to the winding die 30 before winding to the winding die 30, and for the cylindrical coil, the spring back Can be reliably eliminated, and dimensional accuracy can be enhanced. In addition, regardless of the rigidity of the metal sheet 2, the metal sheet 2 can be accurately wound around the winding die to prevent deviation, and the first embodiment can be made excellent in manufacturing efficiency and quality, etc. It produces the same effect as the form.
　なお、第２実施形態の曲げ装置３１は、上記したようにフィーダとしての機能を併せ持つ構成としてもよいし、第１実施形態のフィーダ１４と同様のフィーダを、曲げ装置３１の入側近傍位置に配置してもよい。 The bending device 31 of the second embodiment may be configured to have a function as a feeder as described above, or a feeder similar to the feeder 14 of the first embodiment may be placed near the entrance side of the bending device 31. It may be arranged.
　以上、本発明のいくつかの実施形態を説明したが、これらの実施形態は、例として提示したものであり、発明の範囲を限定することは意図していない。これら新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略，置き換え、変更を行うことができる。これら実施形態やその変形は、発明の範囲や要旨に含まれるとともに、特許請求の範囲に記載された発明とその均等の範囲に含まれる。 While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the invention. These novel embodiments can be implemented in other various forms, and various omissions, replacements and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and the gist of the invention, and are included in the invention described in the claims and the equivalent scope thereof.

Claims (7)

  1. 　帯状の金属シートを巻回した巻回体から当該金属シートを繰り出す繰出手段と、前記繰出手段により繰り出した金属シートを回転しながら巻き取る巻型とを備えたコイルの製造装置であって、
    　前記繰出手段と前記巻型との間に設けられ、前記繰出手段により繰り出した金属シートを前記巻型側へ送るフィーダと、
    　前記フィーダにより送られる金属シートに対して、前記巻型へ巻き取る前に曲げ加工を行う曲げ手段と、
    　前記金属シートについて、前記巻型に対する巻き初めを当該巻型の外周形状に合わせた形状とし、以後、その巻型に重ね巻きされる金属シートの外周形状に合わせた形状となるよう、前記フィーダによる前記金属シートの送り量に基づき前記曲げ手段の曲げ加工を制御する制御手段とを備え、
    　前記制御手段により前記曲げ加工を制御することで、前記巻型における金属シートの巻き取り量に応じた曲げ癖を、当該巻型への巻き取り前に付与する構成としたことを特徴とするコイルの製造装置。     An apparatus for manufacturing a coil comprising: a feeding means for feeding the metal sheet from a wound body in which a band-like metal sheet is wound; and a winding form for winding the metal sheet fed out by the feeding means while rotating it.
    A feeder provided between the feeding means and the winding form, for feeding the metal sheet being fed out by the feeding means to the winding form side;
    Bending means for bending the metal sheet fed by the feeder before winding it into the form;
    The metal sheet has a shape in which the winding start with respect to the winding mold is matched to the outer peripheral shape of the winding mold, and thereafter the feeder is formed by the feeder so as to conform to the outer peripheral shape of the metal sheet And control means for controlling bending of the bending means based on the feed amount of the metal sheet,
    A coil characterized in that by controlling the bending process by the control means, a bending crease corresponding to the winding amount of the metal sheet in the winding die is applied before winding up on the winding die. Production equipment.
  2. 　前記巻型の外周形状は、その回転軸の軸線方向から見て多角形をなし、
    　前記曲げ手段は、前記金属シートに対して、前記巻型の角、或は当該巻型に重ね巻きされる金属シートの角に対応した折り曲げ癖を形成するように構成されていることを特徴とする請求項１記載のコイルの製造装置。     The outer peripheral shape of the winding form has a polygonal shape when viewed from the axial direction of its rotation axis,
    The bending means is configured to form, with respect to the metal sheet, a bending bar corresponding to a corner of the winding form or a corner of a metal sheet to be lap wound on the winding form. The manufacturing apparatus of the coil according to claim 1.
  3. 　前記巻型の外周形状は、その回転軸の軸線方向から円環状をなし、
    　前記曲げ手段は、前記金属シートに対して、前記軸線方向から見たときの前記巻型の曲率、或は当該巻型に重ね巻きされる金属シートの曲率に対応した湾曲癖を形成するように構成されていることを特徴とする請求項１記載のコイルの製造装置。     The outer peripheral shape of the winding form has an annular shape from the axial direction of the rotation axis,
    The bending means forms, with respect to the metal sheet, a curvature corresponding to a curvature of the winding form as viewed in the axial direction or a curvature of a metal sheet wound on the winding form. The coil manufacturing apparatus according to claim 1, wherein the coil manufacturing apparatus is configured.
  4. 　前記フィーダ及び曲げ手段は、前記製造装置において相互に近接する配置としたことを特徴とする請求項１から３のいずれか一項記載のコイルの製造装置。 The coil manufacturing apparatus according to any one of claims 1 to 3, wherein the feeder and the bending means are disposed close to each other in the manufacturing apparatus.
  5. 　前記繰出手段と前記フィーダとの間に設けられ、前記繰出手段から繰り出された金属シートの巻き癖を矯正するレベラーを備えることを特徴とする請求項１から４のいずれか一項記載のコイルの製造装置。 The coil according to any one of claims 1 to 4, further comprising a leveler which is provided between the feeding means and the feeder and which corrects a curl of a metal sheet fed from the feeding means. manufacturing device.
  6. 　帯状の金属シートを巻回した巻回体から当該金属シートを繰り出す繰出手段を備え、前記繰出手段から繰り出した金属シートを巻型に巻き取ることによりコイルを製造する方法であって、
    　前記繰出手段と前記巻型との間に設けられたフィーダにより、前記繰出手段から繰り出した金属シートを前記巻型側へ送る送り工程と、
    　前記フィーダにより送られる金属シートに対して、前記巻型へ巻き取る前に曲げ加工を行う曲げ行程と、を備え、
    　前記曲げ行程において、
    　前記フィーダによる前記金属シートの送り量に基づき、前記金属シートについて、前記巻型に対する巻き初めを当該巻型の外周形状に合わせた形状とし、以後、その巻型に重ね巻きされる金属シートの外周形状に合わせた形状となるよう前記曲げ加工が行われ、
    　前記曲げ加工によって、前記巻型における金属シートの巻き取り量に応じた曲げ癖を、当該巻型への巻き取り前に付与することを特徴とするコイルの製造方法。     A method of manufacturing a coil by providing a feeding means for feeding the metal sheet from a wound body in which a band-like metal sheet is wound, and winding the metal sheet fed from the feeding means in a winding die,
    Feeding a metal sheet fed out from the feeding means to the winding form by a feeder provided between the feeding means and the winding form;
    And a bending step of bending the metal sheet fed by the feeder before winding it into the winding form,
    In the bending process,
    Based on the feed amount of the metal sheet by the feeder, the metal sheet has a shape in which the beginning of winding with respect to the winding die is matched to the outer peripheral shape of the winding die, and thereafter the outer periphery of the metal sheet to be lap wound in the winding die. The bending process is performed to have a shape that matches the shape,
    A method of manufacturing a coil, comprising: applying a bending crease corresponding to the winding amount of the metal sheet in the winding die by the bending process before winding the winding on the winding die.
  7. 　帯状の金属シートを巻回した巻回体から当該金属シートを繰り出して、巻型に巻き取ることにより構成されたコイルであって、
    　前記金属シートは、前記巻型へ巻き取る前に曲げ加工を行う曲げ手段によって、
    　前記巻型に対する巻き初めを当該巻型の外周形状に合わせた形状とし、以後、その巻型に重ね巻きされる金属シートの外周形状に合わせた形状となるよう、前記巻型における金属シートの巻き取り量に応じた曲げ癖が、当該巻型への巻き取り前に形成された構成にあることを特徴とするコイル。     A coil configured by unrolling a metal sheet from a wound body in which a band-shaped metal sheet is wound, and winding the metal sheet in a winding form,
    The metal sheet is bent by bending means before being wound into the winding form.
    The winding of the metal sheet in the winding mold is performed so that the winding start of the winding die conforms to the outer peripheral shape of the winding die, and thereafter, the shape conforms to the outer peripheral shape of the metal sheet wound on the winding die. A coil characterized in that a bending rod corresponding to the amount taken is in a configuration formed before winding into the winding form.
PCT/JP2013/078292 2012-11-07 2013-10-18 Coil and fabrication device therefor, and coil fabrication method WO2014073352A1 (en)

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