JP3490524B2 - Coil manufacturing apparatus and manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and method for manufacturing a sheet winding type coil used in, for example, a transformer.

[0002]

32 is a side view showing an example of a conventional coil manufacturing apparatus, and FIG. 33 is a perspective view of FIG. In the figure, 1 is a reel, 2 is a reel on which the reel 1 is attached, 3 is a pulley A attached to the reel 2, 4 is a reel 1
, 5 is a pulley B attached to the drive motor 4, 6 is a timing belt wound between the pulleys A3 and B5, 7 is a winding shaft 2, a pulley A3, a drive motor 4, a pulley B5 And an outer box A for accommodating the timing belt 6.

Reference numeral 8 is a metal sheet made of a thin metal material wound in a coil shape, 9 is a mounting shaft of the metal sheet 8, 10 is a roller guide for guiding the metal sheet 8, and 11 is a coiled first sheet. 2, insulating paper 12, a mounting shaft for the second insulating paper 11, 13 a roller guide for guiding the second insulating paper 11,
14 is the first insulating paper wound in a coil, and 15 is the first
Mounting shaft of the insulating paper 14, 16 is a roller guide for guiding the first insulating paper 14, 17 is an outer box B to which the mounting shafts 9, 12, 15 and the roller guides 10, 13, 16 are fixed. is there.

The width of the metal sheet 8 is smaller than that of the second insulating paper 11 and the first insulating paper 14.
Furthermore, the reason why the two sheets of the second insulating paper 11 and the first insulating paper 14 are stacked and used is to prevent a short circuit when the insulating paper is damaged.

Another conventional technique relates to a band duct forming an insulating oil flow path inside a coil of a transformer using insulating oil. The band duct cuts a press board to form a duct piece, and an adhesive is applied to a craft tape. Band duct automatic production machine to be attached by using the actual machine Sho 59-98638
It is disclosed in the publication.

Next, a conventional coil manufacturing method for a transformer will be described. First, the metal sheet 8 and the second insulating paper 11
Then, the respective ends of the first insulating paper 14 are fixed to the reel 1 with tape or the like. Next, the start switch (not shown) of the drive motor 4 is operated to rotate the winding frame 1 to wind the metal sheet 8, the second insulating paper 11 and the first insulating paper 14 at the same time. The drive motor 4 automatically stops at a position preset in a control device such as a programmable controller. Then, the lead or the duct sheet is attached at the stop position. The duct sheet is for filling the space between the coil sheets with the oil filled in the coil case to have a function of cooling the heat generated during the transformation of the transformer.

Next, the attachment of the leads and the duct sheet will be described. First, when the stop position of the bobbin 1 is a position for welding the lead, the metal sheet 8 is cut using a cutting tool (not shown), and further sanding or the like is performed to return the cut surface or burr. Get rid of. At this time, as shown in FIG. 34, a chip receiving cover 18 is laid under the metal sheet 8 to prevent the chips from adhering to the product. The chip receiving cover 18 is carefully removed after the above cutting and filing.

Next, as shown in FIG. 35, the metal sheet 8
The backing plate 19 is laid under the lead plate, and the lead plate 20 is placed thereon. Then, the metal sheet 8 is covered on the lead plate 20, and the metal sheet 8 is hit with a square bar 21 or the like to form the metal sheet 8 so as to be in close contact with the lead plate 20. After this,
As shown in FIG. 6, the spot welding torch 22 is pressed against the metal sheet 8 to connect the metal sheet 8 and the lead plate 20 by spot welding.

After spot welding, the backing plate 19 is removed, the metal sheet 8 and the lead plate 20 are fixed with tape,
By operating the start switch again, the reel 1 is rotated again to the preset stop position.

On the other hand, when the stop position of the bobbin 1 is the mounting position of the duct sheet, as shown in FIG.
With varnish, glue, etc. on the metal sheet 2
Apply 4 Next, as shown in FIG. 38, the rod-shaped wood 25
Affixed to the paper tape 26 to form a double-sided duct sheet 27
Is formed, and the portion of the paper tape 26 is attached to the adhesive 24. Further, as shown in FIG. 39, the duct sheet 27 is fixed to the metal sheet 8 with the tape 27A so that the duct sheet 27 does not come off.

After that, the start switch of the drive motor 4 is pressed again to rotate the reel 1 a predetermined number of times, and the first insulating paper 14, the second insulating paper 11 and the metal sheet 8 are wound on the reel 1 in a superposed manner. Then, the reel 1 is stopped. By performing the above operation several times, a plurality of duct sheets 27a to 27d are incorporated in the coil as shown in FIG.

After the above, when the end of winding is reached and the rotation of the winding frame 1 is stopped, the lead plate 20 is welded and fixed with tape in the same manner as above. Then, the winding frame 1 is rotated to wind the second insulating paper 11 and the first insulating paper 14 by a predetermined number of turns. Finally, the second insulating paper 11 and the first insulating paper 14 are cut, and the ends are fixed with tape.

In the above example, the adhesive 24 is applied on the metal sheet 8 to adhere the duct sheet 27.
In the case where the adhesive 24 is applied to the first insulating paper 14 as shown in FIG. 1 and the duct sheet 27 is arranged between the first insulating paper 14 and the second insulating paper 11 as shown in FIG. is there.

As described above, a sheet winding type coil is manufactured by welding the lead plate 20 or adhering the duct sheet 27 every time the reel 1 is stopped at the preset position. It

[0015]

In the above-described conventional coil manufacturing method, most of the work is manual work, and moreover, it involves cutting work and spot welding work which can be performed only by a skilled worker. However, there is a problem that a great amount of manufacturing time is required and that the finished outer diameter of the coil, the position of the lead plate 20, the position of the duct sheet 27, and the like vary depending on the skill of the operator. Especially in the case of manually adhering the duct sheet 27,
In some cases, a sufficient adhesive force could not be obtained, and the duct sheet 27 was misaligned, which necessitated reworking.

The present invention has been made to solve the above-mentioned problems, and it is possible to shorten the manufacturing time by automating the work and to stabilize the quality of the coil. An object is to obtain a manufacturing apparatus and a manufacturing method.

[0017]

[0018]

[0019]

In the method for manufacturing a coil according to the present invention, a step of rotating a winding frame to wind the metal sheet, the first insulating paper and the second insulating paper on the winding frame in a superposed manner. And a step of stopping the rotation of the winding frame after winding a predetermined amount of the metal sheet, the first insulating paper and the second insulating paper, and a longitudinal direction of the metal sheet below the portion before winding the metal sheet. A step of transporting a lead plate provided with a slit extending in a direction intersecting with the step of welding the metal sheet and the lead plate on both sides of the slit, and a rotation of the winding frame, thereby making the metal sheet and the first insulation Winding the paper and the second insulating paper, moving the lead plate welded to the metal sheet by a predetermined amount, and then stopping the rotation of the winding frame; cutting the metal sheet at the slit position; By rotating the frame, the metal Over bets, it is intended to include the step of lead plate, taking up the first insulating sheet and the second insulating paper reel.

Further, the coil manufacturing apparatus according to the present invention is a reel rotating device for winding the metal sheet, the first insulating paper and the second insulating paper on the reel by rotating the reel. Of the stacked lead plates, the uppermost lead plate includes a contact plate that abuts the upper surface of the uppermost lead plate, a pair of open / close fixed claws, and a pair of swingable swing claws that open / close together with the fixed claws. A lead plate take-out device having a hand for gripping, a vertical movement mechanism for moving the touch plate and the hand up and down, and a moving mechanism for moving the touch plate and the hand in the horizontal direction; The present invention is provided with a lead plate transporting device for transporting the lead plate below a portion of the metal sheet before winding, and a welding device for welding the lead plate transported by the lead plate transporting device to the metal sheet.

Further, the coil manufacturing apparatus according to the present invention is a reel rotating device for winding the metal sheet, the first insulating paper and the second insulating paper on the reel by rotating the reel. A lead plate take-out device for taking out the laminated lead plates one by one, a guide rail extending below a portion before winding of the metal sheet, and a carrier table movably provided along the guide rail, A lead plate having a clamp mechanism provided on the carrier table for clamping the lead plate taken out by the lead plate take-out device, a carrier mechanism for moving the carrier table along the guide rails, and a stopper for positioning the carried lead plate. A transport device, a metal sheet lifting device that lifts a metal sheet when the lead plate is transported under a metal sheet by the lead plate transport device, and a lead plate transport device. The conveyed lead plate in which with a welding device for welding the metal sheets.

Further , the coil manufacturing apparatus according to the present invention is a reel rotating device for winding the metal sheet, the first insulating paper and the second insulating paper on the reel by rotating the reel. A welding device for welding a lead plate provided with a slit extending in a direction intersecting the longitudinal direction of the metal sheet to the lower surface of the portion of the metal sheet before winding, and welding provided on the winding frame side of the welding device. A die on which a lead plate is placed, a punch holder that is vertically movable above the die, and a punch that is detachably attached to the punch holder and that cuts the metal sheet at the slit portion by the downward movement of the punch holder. And a cutting device having a stripper plate that is vertically movable in a punch holder and presses a lead plate onto a die, and a sensor that detects a cutting position of a metal sheet.

Further, the coil manufacturing apparatus according to the present invention comprises a reel rotating device for winding the metal sheet, the first insulating paper and the second insulating paper on the reel by rotating the reel. , A welding device that welds the lead plate to the portion before winding of the metal sheet, a guide rail provided on the winding frame side of this welding device, and a reciprocating part along the guide rail in the length direction of the metal sheet. The guide roller is movably provided with a guide roller for guiding the metal sheet, and a driving means for moving the guide roller along the guide rail.

[0024]

[0025]

[0026]

In this invention, the manufacturing time of the coil is shortened by the automation of the work, the variation of the welding position between the metal sheet and the lead plate is prevented, and the cut surface of the metal sheet is finished. It is possible to prevent the occurrence of variations, and thereby obtain a product with stable quality with little variation in outer shape and electrical characteristics.

Further , in the present invention, since the lead plate is gripped by the pair of fixed claws and the pair of swing claws, even if the width of the gripped portion of the lead plate is different, the difference in the widths fluctuates. Within the swing range of the moving claw, it can be stably gripped and taken out. Further, since the contact depth between the fixed claw and the swing claw and the lead plate can be made constant by bringing the contact plate into contact with the lead plate, the lead plate can be stably gripped and taken out.

Further , according to the present invention, the work of conveying and positioning the lead plate and stacking the metal sheets are automatically performed, which makes it possible to shorten the coil manufacturing time and to prevent the welding position of the lead plate from varying. To prevent.

Further , according to the present invention, since the slit is used as a die to cut the metal sheet so as to tear off the metal sheet, the metal sheet can be cut even if the lead plate is made of a soft material. Further, since the metal sheet 8 can be cut even if there is some chamfer or R at the corners of the slit, the number of manufacturing steps of the lead plate can be reduced.

Further , in the present invention, the movement of the metal sheet is stopped before the lead plate passes the guide roller, and the guide roller is moved along the guide rail by the driving means to pass the lead plate. This prevents the lead plate welded to the metal sheet from being pressed against the guide roller and bent.

[0031]

Embodiments of the present invention will be described below with reference to the drawings. Example 1. 1 is a block diagram showing a coil manufacturing apparatus according to a first embodiment of the present invention, and FIG. 2 is a sectional view taken along the line II-II of FIG. 1, and the same or corresponding parts as in FIGS. The description is omitted.

In the figure, 4a is a positioning control motor for rotating the winding shaft 2, which is housed in an outer box A7.
Reference numeral 8 denotes a discharging device as a means for discharging an instant adhesive, which is provided on the upper part of the moving path of the first insulating paper 14 wound on the reel 1 and has a width of the first insulating paper 14 as shown in FIG. Discharge devices 28a, 28b are arranged at intervals narrower than the size. As the above-mentioned instant adhesive, cyano-based and bond-based instant adhesives are generally used. The reason why the instant adhesive is used is that, in order to promote automation, if the adhesive dries slowly, the time to move to the next step is delayed.

Reference numeral 29 is a suction pad for sucking the paper tape 26 of the duct sheet 27. As shown in FIG. 2, the suction pads 29a to 29d are arranged at positions where the duct sheet 27 can be sucked.
It is arranged in several places. Reference numeral 30 is a pipe for fixing the suction pad 29, 31 is a tube for sending air connected to the pipe 29, 32 is a spring provided outside the pipe 30, and 33 is a bush serving as a guide for sliding the pipe 30 up and down. 34 is a pusher as a pressurizing means for pressurizing the rod-shaped wood 25, 35 is a plate to which the bush 33 and the pusher 34 are attached, 36 is a cylinder for moving the plate 35 up and down by air or hydraulic pressure, and 37 is a receiving plate. Further, a control device for adjusting the pressure of air or hydraulic pressure in the cylinder 36, a pressure regulator, a control device such as a solenoid valve, and an adjusting device are provided.

If a heater such as a heater is provided below the receiving plate 37 to heat the adhesive applied to the first insulating paper 14, the drying of the adhesive can be promoted.
The suction pad 29, the pipe 30, the spring 32, the bush 33, the pusher 34, the plate 35, and the cylinder 36.
The one configured by the above is hereinafter referred to as a duct sheet supply device.

Further, in this Embodiment 1, the instant adhesive is applied to the surface of the first insulating paper 14, but this may be applied to the surface of the metal sheet 8 as in the conventional method. This is because a welding device for connecting the lead wire to the metal sheet 8 by welding is required, and the arrangement of the discharging device 28 in addition to this welding device is restricted by the configuration of this device.

Next, the operation will be described. First, the metal sheet 8, the second insulating paper 11 and the first insulating paper 14 are fixed to the reel 1. Next, start switch (not shown)
Press to drive the positioning control motor 4a and rotate the reel 1. Thereby, the metal sheet 8 and the second insulating paper 1
The 1st and 1st insulating paper 14 is rolled up simultaneously. The positioning control motor 4a rotates by a preset rotation amount according to a command signal from a control device such as a programmable controller.

On the other hand, as shown in FIG. 2, wood 25 which is a rod-shaped duct forming member (wood, resin, base paper, etc. can be used) is attached to a paper tape 26 to form a cross-shaped duct sheet 27. Store in a stocker (not shown). Such duct sheets 27 are taken out one by one from the duct sheet stocker by the suction pad 29 of the duct sheet supply device, and are conveyed to the upper part of the first insulating paper 14 by the conveying device (not shown) to stand by. .

The above-mentioned transfer device includes a horizontal transfer means for transferring the suction pad 29 to the upper part of the first insulating paper 14, and a first transfer means.
And a vertical transfer means for transferring the insulating paper 14 to a predetermined position. Each of the above transfer means is
It is driven by an air cylinder.

Next, the reel 1 is rotated a predetermined number of times to move the position where the duct sheet 27 of the first insulating paper 14 is attached to the position below the instantaneous adhesive discharge device 28, and at the same time, as shown in FIG.
As shown in FIG.
Instant adhesive 40 is ejected from 8. At this time, as shown in FIG. 3, the first insulating paper 14 is moved by a predetermined amount by the rotation of the winding frame 1 by θ1, and as shown in FIG. 4, which is a sectional view taken along line IV-IV in FIG. On the first insulating paper 1
Instant adhesive 40a, 40b is applied to the surface of No. 4 in a predetermined length.

Next, as shown in FIG. 5, the winding frame 1 is rotated by θ2 and the position where the duct sheet 27 of the first insulating paper 14 is attached, that is, the portion where the instant adhesives 40a and 40b are applied is the duct. When it moves below the sheet feeding device, the rotation of the reel 1 is temporarily stopped and positioned. The duct sheet supply device is provided with a confirmation device (not shown) including a micro switch and an alarm device for detecting whether or not the duct sheet 27 has moved to a portion where the instantaneous adhesives 40a and 40b are applied. ing. The confirmation device may be configured to confirm whether or not the portions coated with the instantaneous adhesives 40a and 40b have been transferred to the lower portion of the position where the duct sheet 27 is on standby.

The signal confirmed by the confirmation device is
It is sent to the control device, and if it is correct, the duct sheet feeding device is lowered by the cylinder 36 by the command signal. Next, as shown in FIG. 6, the instantaneous adhesive 40 on which the paper tape 26 of the duct sheet 27 is discharged onto the first insulating paper 14 while the duct sheet supply device is being lowered by the cylinder 36.
The rod-shaped wood 25 is pressed by the operation of the pusher 34 by being fixed by the suction pad 29 on the upper part of the duct sheet feeding device by the cylinder 36, and the wood 25 is moved in the length direction of the metal sheet 8. The duct sheet 27 is attached to the first insulating paper 14 so as to be at a right angle.

Although the wood tape 25 is attached to the paper tape 26 in this embodiment, the paper tape 2
The wood 25 may be directly attached to the portions of the instant adhesives 40a and 40b without using 6.

After the above, as shown in FIG. 7, the duct sheet feeding device is raised by the cylinder 36. And FIG.
As shown in FIG. 9, when the winding frame 1 is rotated again, the first insulating paper 14 to which the duct sheet 27 is attached is moved, and when the winding frame 1 is further rotated, it is placed on the coil. The duct sheet 27 will be wound up.

By repeating such operations, the coil of the transformer as shown in FIG. 40 is manufactured. As a matter of course, the reel 1 has the metal sheet 8 and the second insulating paper 1
Considering that the first and the first insulating papers 14 become thicker as they are rolled up, the timing of applying the adhesive 40 and the timing of supplying the duct sheet 27 to the control device such as the programmable controller described above. The correction value for is input in advance.

As described above, since the manual work is replaced by the machine, the assembly position of the duct sheet 27 becomes uniform, so that the quality of the product can be made uniform. Further, in the conventional device, the duct sheet 27 can be quickly fixed to the metal sheet 8 by the tape 27A (FIG. 39) used, but the duct sheet 27 is easily peeled off from the metal sheet 8, while the adhesive 24 dries. However, according to the present invention, since the adhesive 40 is an instant adhesive, it dries quickly and is easy to manufacture. The time can be shortened. Also, without using instant adhesive,
Even if an adhesive similar to the conventional one is used, the drying of the adhesive can be promoted by heating it with a heater.

Example 2. Next, FIG. 10 is a block diagram showing a configuration of a coil manufacturing apparatus according to a second embodiment of the present invention. In the figure, reference numeral 41 is a lead plate stocker for accommodating a plurality of lead plates 42 as shown in FIG. 11, and the lead plate 42 used in the second embodiment is provided with a slit 42a.

Reference numeral 43 is a lead plate take-out device for taking out the lead plates 42 one by one from the lead plate stocker 41, 44 is a lead carrying device for carrying the lead plates 42 taken out by the lead plate taking-out device 43 to below the metal sheet, and 45 is Lead plate 42
A metal sheet lifting device (upper and lower lifter) for lifting the metal sheet at a position where the sheet is conveyed, 46 is a welding device for welding the lead plate 42 to the metal sheet, and 47 is a slit 42a for the metal sheet where the lead plate 42 is welded. It is a cutting device for cutting along.

Reference numeral 48 is a reel rotating device for winding the metal sheet, the first insulating paper and the second insulating paper on the reel by rotating the reel, and 49 is a double-sided tape for attaching a double-sided tape to the metal sheet. A tape sticking device, 50 is a duct sheet stocker for accommodating a plurality of duct sheets, and 51 is a duct sheet stocker 50 that takes out the duct sheets one by one and conveys them onto a first insulating paper. 1 is a duct sheet sticking device for sticking to No. 1 insulating paper.

Reference numeral 52 denotes the lead plate take-out device 43, the lead plate transfer device 44, the metal sheet lifting device 45, the welding device 46, the cutting device 47, the reel rotating device 48, the double-sided tape sticking device 49 and the duct sheet sticking device. The control device 52 controls the 51 and the like, and the control device 52 has a position determination unit 53 that determines the position where the duct sheet is attached.

In FIG. 10, the solid line arrows show the flow of control signals, the broken line arrows show the flow of lead plates, and the dashed line arrows show the flow of duct sheets.

Next, the operation will be described. FIG. 12 is a flowchart explaining the operation of the control device 52 of FIG. First, the winding frame is set on the winding shaft of the winding frame rotating device 48, and the ends of the metal sheet, the first insulating paper, and the second insulating paper wound in a coil shape on each supply device are taped or the like. Each is fixed to the reel. After that, the reel is rotated by the reel rotating device 48 (step S1).

During the rotation of the bobbin, the position discriminating unit 53 of the control unit 52 determines whether it is the position to attach the duct sheet to the first insulating paper (step S2) or the position to weld the lead plate 42 to the metal sheet. (Step S3), it is determined whether or not it is the position for cutting the metal sheet (Step S4) and whether or not the product is completed (Step S5).

Information such as the positions and the numbers of the duct sheets to be attached and the positions and the numbers of the lead plates to be welded are input to the control device 52 in advance. This information is
For example, attaching the duct sheet with two turns of the bobbin, four turns and four
The duct sheet is attached at 0 ° and the lead plate is welded at 6 rotations and 50 °.

After starting the rotation of the bobbin in such a state, when the position of attaching the duct sheet of the first insulating paper is reached (step S2), the rotation of the bobbin is first stopped (step S6). Subsequently, the duct sheet attaching device 51 takes out the duct sheet from the duct sheet stocker 50, and the double-sided tape attaching device 49 attaches the double-sided tape to the first insulating paper (step S7).
Then, the duct sheet attaching device 51 conveys the duct sheet and attaches it to the first insulating paper via the double-sided tape (step S8). When the series of pasting work is completed, the reel is rotated again (step S1).

When the lead plate welding position of the metal sheet is reached (step S3), the rotation of the bobbin is first stopped (step S9). Then, the lead plate take-out device 43 takes out the lead plate 42 from the lead plate stocker 41, and the metal sheet at the lead plate welding position is lifted by the metal sheet lifting device 45 (step S10). After that, the lead plate conveying device 44 conveys the lead plate 42 below the metal sheet at the welding position, and the welding device 46 welds the lead plate 42 and the metal sheet (step S11). When a series of welding work is completed,
The reel is rotated again (step S1).

Further, when it is determined that the position for cutting the metal sheet overlapping the slit 42a of the lead plate 42 has reached the cutting position of the cutting device 47 (step S4).
The reel is stopped and positioning is performed (step S1).
2). Then, only the metal sheet is cut by the cutting device 47 (step S13). When the metal sheet is cut, the reel is rotated again (step S1). Furthermore, when it is determined that each sheet reaches the winding end position and the product is completed (step S5), the winding frame is stopped (step S14), and the standby state is set.

After that, the connecting portion 42b (FIG. 11) of the lead plate 42 is cut by a nipper or the like. Further, since the lead plate 42 is usually welded to the winding end portion of the metal sheet, when the connecting portion 42b of the lead plate 42 is cut and divided into both sides of the slit 42a, the winding end metal sheet is also cut. It At this time, the separated half of the lead plates 42 are arranged at the winding start of the next coil. As described above, after the metal sheet at the end of winding is cut,
And the second insulating paper is also cut and the winding end is fixed. Finally, the operator removes the product from the reel.

As described above, according to the second embodiment, the coil manufacturing time can be shortened by the automation of the work. Further, it is possible to prevent variations in the welding position between the metal sheet and the lead plate 42, and to prevent variations in the finished state of the cut surface of the metal sheet, and thus variations in outer shape and electrical characteristics. It is possible to obtain products with few and stable quality.

By setting the double-sided tape sticking position by the double-sided tape sticking device 49 and the duct sheet sticking position by the duct sheet sticking device 51 to the same position, the reel stop position at the time of sticking the duct sheet becomes one point. And the manufacturing time is shortened.

Next, FIG. 13 is a front view showing an example of the lead plate take-out device, FIG. 14 is a right side view of FIG. 13, and FIG. 15 is FIG.
4 is a sectional view taken along line XV-XV of FIG. In the figure, a lead plate stocker 41 for accommodating and stacking a plurality of lead plates 42 is
It has guides 41a to 41d. Reference numeral 61 is four columns that are erected on the installation surface, 62 is a fixing plate fixed to the column 61, and 63 is mounted on the column 61 in parallel with each other.
Book rail, 64 is rail 63 via linear guide 65
A movable table which is provided above and reciprocates along the rail 63,
A cylinder 66 is fixed on the fixed plate 62 and reciprocates the moving table 64.

67 is an upper and lower cylinder fixed to the moving base 64, and 68 is a joint 69 at the lower end of the upper and lower cylinder 67.
The hand fixing plate 68, 70 is two guide shafts fixed to the upper surface of the hand fixing plate 68, 71 is a bearing of the guide shaft 68 provided on the moving base 64, and 72 is the hand fixing plate 68. It is a backing plate attached to the lower part via a connecting rod 73.

74 is a hand body fixed to the hand fixing plate 68, 75 is a finger attached to the hand body 74, 76 is a claw fixing plate fixed to the finger 75, and 77 is a fixing fixed to the claw fixing plate 76. Claw 78 is a claw fixing plate 76
Is fixed to the guide block, and 79 is the guide block 7.
A rocking claw that rocks around a shaft 80 provided on
1 is a stopper that is fixed to the guide block 78 by a fixing nut 82 and restricts the swing range of the swing claw 79, and 83 is provided between the guide block 78 and the swing claw 79, and the swing claw 79 is held in the gripping direction. It is a spring that urges to.

Next, the operation will be described. First, the upper and lower cylinders 67 are driven to lower the hand fixing plate 68 and the mechanism mounted on the hand fixing plate 68, so that the contact plate 72 contacts the uppermost lead plate 42 in the lead plate stocker 41. After that, the hand body 74 is closed, the swinging claw 79 first comes into contact with the end surface of the lead plate 42, and then, as shown in FIG.
7 contacts the end face of the lead plate 42, and the lead plate 42 is gripped.

At this time, L1 size in FIG. 13> L in FIG.
Since the size is two, the swinging claw 79 comes into contact with the end surface of the lead plate 42 first. The swinging claw 79 is fixed to the fixed claw 77.
Until the spring contacts the end surface of the lead plate 42.
Swing against. After the lead plate 42 is gripped by the hand as described above, the hand is moved upward by driving the upper and lower cylinders 37. Then, the moving table 64 is moved along the rail 63 by driving the cylinder 66.

As described above, in the lead plate take-out device of this embodiment, since the pair of fixed claws 77 and the pair of swing claws 79 are provided, the width of the gripped portion of the lead plate 42 is different. However, if the width difference is within the swing range of the swing claw 79, it can be stably gripped and taken out. Further, as shown in FIG. 16, by bringing the contact plate 72 into contact with the lead plate 42, the contact depth L3 between the fixed claw 77 and the swing claw 79 and the lead plate 42 can be made constant, so that L3. If the lead plate 42 has a larger plate thickness, it can be stably gripped and taken out. In this way, since the lead plates 42 having different widths and thicknesses can be gripped and conveyed, a wide range of correspondence is possible.

Next, FIG. 17 is a front view showing an example of the lead plate transporting device, FIG. 18 is a sectional view taken along line XVIII-XVIII of FIG. 17, and FIG. 19 is a plan view of FIG. In the figure, 85
Is a pair of guide rails installed in a direction orthogonal to the moving direction of the metal sheet 8 (vertical direction in FIG. 19), 86 is a carriage that can reciprocate along the guide rails 85, and 87 is a guide for the carriage 86. The rodless cylinder is a transport mechanism that reciprocates along a rail 85.

Reference numeral 88 denotes a clamp cylinder built in the carriage 86. The clamp cylinder 88 is a rotary shaft 88a and a pinion 8 fixed to the rotary shaft 88a.
8b. Reference numeral 89 denotes a pair of parallel circular racks meshing with the pinion 88b, and the pair of circular racks 89 reciprocate in opposite directions by the rotation of the pinion 88b. Reference numeral 90 denotes a first sliding bearing of a round rack 89 fixed to the carrier table 86, and 91 denotes a pair of round racks 89.
Two plates fixed to opposite ends of each other, 92 is a second sliding bearing of the round rack 89 fixed to each plate 91, 93
Is a clamp plate which is fixed to the upper part of each plate 91 and clamps the lead plate 42 placed on the carrier table 86.

Reference numeral 94 denotes a stopper with which the lead plate 42 comes into contact when the lead plate 42 is conveyed by the conveyance table 86, and 95 is an upper and lower lifter as a metal sheet lifting device provided in parallel with the lead plate conveying device. A push-up plate 95a is provided at the upper end of 95.

Next, the operation will be described. First, when the lead plate 42 is placed on the carrier table 86 by the lead plate take-out device as described above, the clamp cylinder 88 is driven, and the circular rack 89 is slid by the rotation of the pinion 88b as shown by the arrow in FIG. The plate 91 moves inward and moves inward. As a result, the clamp plate 93 clamps the lead plate 42 from both sides. On the other hand, the upper and lower lifters 95 are driven,
As shown in FIG. 20, the metal sheet 8 is pushed up.

Thereafter, the carriage 86 is moved by the rodless cylinder 87, and the lead plate 42 is conveyed below the metal sheet 8. At this time, the end surface of the lead plate 42 contacts the stopper 94 for positioning. After that, the metal sheet 8 is lowered by the upper and lower lifters 95, and the metal sheet 8 is stacked on the positioned lead plate 42. In this state, the metal sheet 8 and the lead plate 42 are welded by the welding device.

According to such a lead plate conveying apparatus, since the work of conveying and positioning the lead plate 42 and stacking the metal sheets 8 are automatically performed, the coil manufacturing time can be shortened and the lead plate 42 can be shortened. It is possible to prevent variations in the welding position of, and to stabilize the quality.

Next, FIG. 21 is a front view showing an example of a metal sheet cutting device, and FIG. 22 is a sectional view taken along line XXII-XXII of FIG. In the figure, 100 is a lower plate, 101 is a die fixed on the lower plate 100, 102 is a connecting rod erected on the lower plate 100, 103 is an upper plate fixed on the connecting rod 102, and 104a, 104b. Is the upper plate 103 and the lower plate 100
The sensor is provided inside and detects the slit 42 a of the lead plate 42.

Reference numeral 105 designates a vertical cylinder mounted as a vertical movement mechanism on the upper plate 103, 106 a punch holder connected to the vertical cylinder 105 below the upper plate 103 via a joint 107, and 108 in FIG. The punch is inserted into the punch holder 106 from the left side, and a plurality of rotatable rollers 109 are attached to the upper ends of both side surfaces of the punch 108 as shown in FIG. These rollers 109 are attached to the punch holder 106.
Roll along the guide inside.

110 is provided on the punch holder 106,
A fixing cylinder for pressing and fixing the side surface of the punch 108 into the punch holder 106 via the rod 111, 11
2 is a stopper which is fixed to the punch holder 106 by a fixing nut 113, and the end of the punch 108 is in contact with the stopper.
114 is a bearing fixed in the punch holder 106;
Reference numeral 5 is a rod that is vertically moved by being guided by the bearing 114, 116 is a stripper plate fixed to the lower end of the rod 115, 117 is a spring that pushes down the stripper plate 116, 11
8 is a guide rod whose lower end is fixed to the punch holder 106, and 119 is a guide rod 118 fixed to the upper plate 103.
Is a bearing that guides the vertical movement of the.

Next, the operation will be described. First, the operator pushes a switch (not shown) to move the rod 111 of the fixing cylinder 110 to the left in FIG.
In this state, the punch 108 is inserted into the punch holder 106 from the left side of FIG. At this time, the roller 109 rolls along the guide in the punch holder 106 until the end of the punch 108 contacts the stopper 112.

After inserting the punch 108 into the punch holder 106 in this manner, the punch 108 is fixed in the punch holder 106 by the fixing cylinder 110. As described above, in the apparatus of this embodiment, the replacement of the punch 108 becomes easier and more reliable, and the punch 108 having a different blade width (L4 in FIG. 23) can be easily fixed, so that a wide range of correspondence is possible.

With the punch 108 set as described above, the entire coil manufacturing apparatus is operated. This allows
The metal sheet 8 moves on the die 10. At this time, the slit 42 of the lead plate 42 welded to the metal sheet 8
When the end surface of a is detected by the sensors 104a and 104b, a signal is sent to the control device 52 as shown in FIG. 10 and the rotation of the reel is stopped. FIG. 22 shows the state at this time.

Next, the punch holder 106 is moved down by the upper and lower holders 105. As a result, first the punch 108
The sticks 108a (FIG. 23) provided on both sides of the metal sheet 8 are inserted into the slit 42a, and then the blade of the punch 108 cuts the metal sheet 8 using the slit 42a as a die. At the time of this cutting, the slit 42a is removed by the stripper plate 116.
The metal sheets 8 on both sides of the are pressed. Figure 24
Shows a state after cutting, and 120 is a welding beat.

In such a cutting device, the slit 42a
Width L6 (see FIG. 2) that is slightly smaller than the width L5 (see FIG. 24).
Since the punch 108 of 3) is used and the slit 42a is used as a die to cut the metal sheet 8 by tearing off the metal sheet 8 at the cutting portion, even if the lead plate 42 is made of a soft material, The sheet 8 can be cut. In addition, since the metal sheet 8 can be cut even if there is some chamfer or R at the corner of the slit 42a,
The manufacturing process of the lead plate 42 can be reduced, and the manufacturing cost of the coil as a whole can be reduced.

Furthermore, since the droop 121 of the metal sheet 8 is housed in the slit 42a, the droop 1 during coil winding
21 does not break the upper or lower insulating paper and short-circuit with the metal sheets 8 of the other layers. Furthermore, the punch 108
Is provided with a stick 108a, and when the stick 108a enters the slit 42a before the blade portion, the slit 42a and the blade portion are aligned, so that there is no variation in the cutting state, Is stable.

Next, FIG. 25 is a side view showing a part of the coil manufacturing apparatus of the second embodiment. In the figure, 131 is a support stand that is erected in the vicinity of the reel rotating device 48 that incorporates a servomotor or the like as a drive source, and 132 is the support base 1.
A frame fixed on 31 and a frame 1
A cylinder bracket fixed to 32, a cylinder 134 as a driving unit fixed to the cylinder bracket 133, and a guide rail 135 provided on the frame 132.

A slide plate 136 is connected to the cylinder 134 via a joint 137 and reciprocates in the left-right direction in the drawing along a guide rail 135. 138 is a bearing box provided on the slide plate 136. 139 is a bearing box. It is a guide roller rotatably attached to 138, and this guide roller 139 guides the metal sheet 8. 14
Reference numerals 0a and 140b denote sensors which are fixed to the frame 132 via the sensor bracket 141 and detect the lead plate 42 welded to the metal sheet 8.

Next, the operation will be described. As shown in FIG. 25, when the lead plate 42 welded to the metal sheet 8 reaches the positions of the sensors 140a and 140b and is detected,
This information is sent to the control device 52 as shown in FIG. 10, and the rotation of the reel 1 is stopped. Next, the cylinder 134
Is driven, and as shown in FIG. 26, the guide roller 139 is retracted together with the slide plate 136. At this time, the guide roller 139 passes through the lead plate 42 without being strongly pressed against the guide roller 139.

Thereafter, as shown in FIG. 27, the reel 1 is rotated by the set amount and stopped. And the cylinder 134
Is driven, and as shown in FIG. 28, the guide roller 139 is driven.
Is advanced to its original position. The set amount of rotation of the winding frame after the roller guide retreats is such an amount that the lead plate 42 does not contact the guide roller 139 when the guide roller 139 re-advances. From the state of FIG. 28, the reel 1 is rotated,
Metal sheet 8, second insulating paper 11 and first insulating paper 14
Are piled up and rolled up.

In such a device, the lead plate 42 welded to the metal sheet 8 is prevented from being pressed against the guide roller 139 and bent. Therefore, the outer shape of the product is prevented from being deformed, the dimensional accuracy is improved, the variation in electrical characteristics is eliminated, and the quality is stabilized.

Example 3. Next, FIG. 29 is a block diagram showing a main part of a coil manufacturing apparatus according to a third embodiment of the present invention. In the figure, reference numeral 151 denotes a control device that controls the reel rotating device 48 and the like, and the control device 151 has a storage unit 152. Reference numeral 153 is a metal sheet winding amount measuring device connected to the control device 151, and 154 is a first insulating paper winding amount measuring device connected to the control device 151.

FIG. 30 is a block diagram showing the outline of each winding amount measuring device of FIG. In the figure, the metal sheet winding amount measuring device 153 has a roller 153a that rotates with the movement of the metal sheet 153, and an encoder 153b connected to the roller 153a. Further, the first insulating paper winding amount measuring device 154 includes a roller 154 a that rotates with the movement of the first insulating paper 14 and the roller 154.
an encoder 154b connected to a.

Next, the operation will be described. FIG. 31 is a flow chart for explaining the operation of the device of FIG. When the reel 1 is rotated (step S21) and the winding of the metal sheet 8 and the first and second insulating papers 14 and 11 is started, the reel 151 is set to the predetermined reel 1 in the control device 151. It is determined whether or not it has rotated by an angle. Then, when the winding frame 1 is rotated by a predetermined angle, the winding amount of the metal sheet 8 is measured by the metal sheet winding amount measuring device 153, and the data is sent to and stored in the storage unit 152. The winding amount of the first insulating paper 14 is measured by the insulating paper winding amount measuring device 154, and the data is sent to and stored in the storage unit 152 (step S23).

Thereafter, it is judged whether or not the product is completed (step S24). If the product is not completed, the winding is continued, and the above-mentioned winding amount is measured and stored every time the reel 1 rotates by a certain angle. Be seen. Then, when the product is completed, the reel 1 is stopped (step S25).

Here, the lengths of the metal sheet 8 and the insulating papers 11 and 14 which are wound by one rotation of the reel 1 are different because the reel 1 becomes thicker as the reel rotates.
Therefore, the winding amount for each θ rotation of the reel 1 is measured at the straight line portion on the upstream side of the reel 1.

For example, when the welding position of the lead plate deviates from the correct position by x, the rotation angle θ of the reel 1 at the welding position.
The correction amount of x is calculated from n and the measured winding amount Ln. That is, the encoder pulse of the motor rotating θn is set to P
Then, the moving amount X of the metal sheet 8 per pulse
Becomes X = Ln / P, and the correction pulse amount ρ is ρ = x /
It becomes X. Therefore, by correcting the value of the original lead plate welding position pulse and inputting it to the controller 151, the welding position of the lead plate can be eliminated at the time of manufacturing the next coil. Of course, the same modification can be made for the duct sheet.

[0092]

[0093]

[0094]

The coil manufacturing method of the present invention can shorten the coil manufacturing time by automating the work.
It also prevents variations in the welding position between the metal sheet and the lead plate, and prevents variations in the finished state of the cut surface of the metal sheet, which reduces variations in external shape and electrical characteristics. It is possible to obtain products with stable quality.

Further, since the coil manufacturing apparatus of the present invention grips the lead plate by the pair of fixed claws and the pair of swing claws, even if the width of the gripped portion of the lead plate is different, the width of the gripped part is different. If the difference is within the swing range of the swing claw, it can be stably gripped and taken out, and by contacting the contact plate to the lead plate, the fixed claw, swing claw and lead plate Since the contact depth can be made constant, the lead plate can be stably gripped and taken out.

Further, since the coil manufacturing apparatus of the present invention automatically carries out the work of conveying and positioning the lead plate and stacking the metal sheets, the coil manufacturing time can be shortened and the welding position of the lead plate can be shortened. It is possible to prevent the occurrence of variation and to stabilize the quality.

Further , in the coil manufacturing apparatus of the present invention, the slit is used as a die to cut the metal sheet so as to tear off the metal sheet. Therefore, even if the lead plate is a soft material, the metal sheet is cut. Can be done
In addition, since the metal sheet can be cut even if there is some chamfering or R at the corners of the slit, the manufacturing process of the lead plate can be reduced, and since the punch can be replaced, various lead plates can be used. It has the effect of being able to respond.

Further, in the coil manufacturing apparatus of the present invention, the movement of the metal sheet is stopped before the lead plate passes the guide roller, and the guide roller is moved along the guide rail by the driving means to pass the lead plate. Since it can be done, it is possible to prevent the lead plate welded to the metal sheet from being pressed against the guide roller and bent, and it is possible to prevent the external shape of the product from being deformed,
As a result, it is possible to improve dimensional accuracy, eliminate variations in electrical characteristics, and stabilize quality.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing a coil manufacturing apparatus according to a first embodiment of the present invention.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is an operation explanatory diagram according to the first embodiment of the present invention.

4 is a sectional view taken along line IV-IV in FIG.

FIG. 5 is an operation explanatory diagram according to the first embodiment of the present invention.

FIG. 6 is an operation explanatory diagram according to the first embodiment of the present invention.

FIG. 7 is an operation explanatory diagram according to the first embodiment of the present invention.

FIG. 8 is an operation explanatory diagram according to the first embodiment of the present invention.

FIG. 9 is an operation explanatory diagram according to the first embodiment of the present invention.

FIG. 10 is a block diagram showing a configuration of a coil manufacturing apparatus according to a second embodiment of the present invention.

11 is a perspective view showing a lead plate used in Example 2. FIG.

FIG. 12 is a flowchart illustrating an operation of the control device of FIG.

FIG. 13 is a front view showing an example of a lead plate take-out device.

FIG. 14 is a right side view of FIG.

15 is a sectional view taken along line XV-XV in FIG.

16 is an enlarged view of a main part showing an operating state of the apparatus of FIG.

FIG. 17 is a front view showing an example of a lead plate transport device.

18 is a sectional view taken along line XVIII-XVIII in FIG.

FIG. 19 is a plan view of FIG.

20 is a front view showing an operation state of the apparatus of FIG.

FIG. 21 is a front view showing an example of a metal sheet cutting device.

22 is a sectional view taken along line XXII-XXII in FIG.

23 is a perspective view showing the punch shown in FIG. 21. FIG.

FIG. 24 is a perspective view showing a cut state of the metal sheet.

FIG. 25 is a side view showing a part of the coil manufacturing apparatus according to the second embodiment.

FIG. 26 is a side view showing an operating state of the apparatus of FIG. 25.

FIG. 27 is a side view showing the state of the latter stage of FIG. 26.

28 is a side view showing the state of the latter stage of FIG. 27. FIG.

FIG. 29 is a block diagram showing a main part of a coil manufacturing device according to a third embodiment of the present invention.

FIG. 30 is a configuration diagram showing an outline of each winding amount measuring device of FIG. 29.

31 is a flowchart illustrating the operation of the apparatus of FIG. 29.

FIG. 32 is a side view showing an example of a conventional coil manufacturing apparatus.

FIG. 33 is a perspective view of FIG. 32.

34 is a perspective view showing a lead welding operation for the coil of FIG. 32. FIG.

FIG. 35 is a perspective view showing a work state of the latter stage of FIG. 34.

FIG. 36 is a perspective view showing a work state of the latter stage of FIG. 35.

FIG. 37 is a perspective view showing an operation of attaching a duct sheet to the coil of FIG. 32.

38 is a perspective view showing a work state in the latter stage of FIG. 37. FIG.

FIG. 39 is a perspective view showing a work state at the latter stage of FIG. 38.

FIG. 40 is a perspective view showing a coil in which a duct sheet is incorporated.

41 is a perspective view showing another example of the work of attaching the duct sheet to the coil of FIG. 32. FIG.

42 is a perspective view showing a work state of the latter stage of FIG. 41. FIG.

[Explanation of symbols]

1 reel 4a positioning control motor (driving means), 8
Metal sheet, 10 mounting shaft (metal sheet feeding means), 1
1 2nd insulating paper, 12 mounting shaft (2nd insulating paper supply means), 14 1st insulating paper, 15 mounting shaft (1st insulating paper supply means), 27 duct sheet, 28 discharge device,
34 pusher (pressurizing means), 42 lead plate, 42a
Slits, 43 Lead plate take-out device, 44 Lead plate conveying device, 45 Metal sheet lifting device, 46 Welding device, 47 Cutting device, 48 Revolving frame rotating device, 66 Cylinder (moving mechanism), 67 Vertical cylinder (vertical moving mechanism) , 72 contact plate, 77 fixed claw, 79 swing claw, 8
5 guide rails, 86 transfer table, 87 rodless cylinder (transfer mechanism), 94 stopper, 95 upper and lower lifters (metal sheet lifting device), 101 die, 104a,
104b sensor, 105 vertical cylinder (vertical movement mechanism), 106 punch holder, 108 punch, 116
Stripper plate, 134 cylinders (driving means), 13
5 guide rails, 136 slide plates, 139 guide rollers.

Claims (5)

(57) [Claims] 1. A step of stacking and winding a metal sheet, a first insulating paper and a second insulating paper on the winding frame by rotating the winding frame, the metal sheet, the first insulating paper and A step of stopping the rotation of the winding frame after winding a predetermined amount of the second insulating paper, and a slit extending in a direction intersecting the longitudinal direction of the metal sheet under a portion before winding of the metal sheet. A step of transporting the lead plate provided with, and a step of welding the metal sheet and the lead plate on both sides of the slit, and by rotating the winding frame, the metal sheet, the first insulating paper And a step of winding the second insulating paper, moving the lead plate welded to the metal sheet by a predetermined amount, and then stopping the rotation of the winding frame, and cutting the metal sheet at the position of the slit. And the process A method for manufacturing a coil, comprising: winding the metal sheet, the lead plate, the first insulating paper, and the second insulating paper on the winding frame by rotating the winding frame. . 2. A reel rotating device that winds the metal sheet, the first insulating paper and the second insulating paper over the reel by rotating the reel, and an uppermost part of the laminated lead plates. A contact plate that abuts the upper surface of the lead plate, a pair of fixed claws that open and close, and a hand that grips the uppermost lead plate by a pair of swingable claws that open and close together with the fixed claw, and the contact plate. And a lead plate take-out device having a vertical movement mechanism for moving the hand up and down and a moving mechanism for moving the pad plate and the hand in the horizontal direction, and the lead plate taken out by the lead plate take-out device and moved. A lead plate transporting device for transporting the sheet below the part before winding, and a welding device for welding the lead plate transported by the lead plate transporting device to the metal sheet. Yl manufacturing apparatus. 3. A reel rotating device that winds the metal sheet, the first insulating paper and the second insulating paper over the reel by rotating the reel, and one laminated lead plate at a time. A lead plate take-out device for taking out, a guide rail extending below the portion before the winding of the metal sheet, a carrier table movably provided along the guide rail, and a lead plate taking-out machine provided on the carrier table. A lead plate transfer device having a clamp mechanism for clamping the lead plate taken out by the device, a transfer mechanism for moving the transfer table along the guide rails, and a stopper for positioning the transferred lead plate, A metal sheet lifting device that lifts the metal sheet when the lead plate is transported below the metal sheet by the transport device, and is transported by the lead plate transport device. An apparatus for manufacturing a coil, comprising a welding device for welding the formed lead plate to the metal sheet. 4. A reel rotating device for winding a metal sheet, a first insulating paper and a second insulating paper on the reel by rotating the reel, and intersecting the longitudinal direction of the metal sheet. A welding device for welding a lead plate provided with a slit extending in the direction to the lower surface of the portion of the metal sheet before winding, and a welded lead plate provided on the winding frame side of the welding device. A die, a punch holder provided above the die so as to be movable up and down, a punch detachably attached to the punch holder for cutting the metal sheet at the slit portion by downward movement of the punch holder, The punch holder is provided so as to be movable up and down, and has a cutting device having a stripper plate for pressing the lead plate onto the die and a sensor for detecting a cutting position of the metal sheet. Manufacturing apparatus of the coil, wherein the door. 5. A reel rotating device for winding a metal sheet, a first insulating paper and a second insulating paper on the reel by winding the reel, and a reel rotating device for winding the metal sheet before winding. A welding device for welding the lead plate to the portion, a guide rail provided on the winding frame side of the welding device, and a reciprocable movement along the guide rail in the length direction of the metal sheet, A coil manufacturing apparatus comprising: a guide roller that guides the metal sheet; and a drive unit that moves the guide roller along the guide rail.