JP4299750B2 - Winding device - Google Patents

Description

  The present invention relates to a winding device.

Conventionally, when manufacturing a coil component by winding a conductive wire around a core portion of a core, there is a coil component in which the conductive wire is wound so that both ends of the conductive wire extend from the outermost peripheral layer of the coil. A winding device for manufacturing such a coil component is disclosed in Patent Document 1.
JP 2001-267171 A

  In the winding device described in Patent Document 1, a core is supported by a jig at the tip of a first rotating shaft that extends to the other side of a first motor provided on one side, and winds one end side of a conducting wire. ing. Further, a second rotating shaft extends coaxially with the rotating shaft of the first motor and extends to one side from a second motor provided on the other side of the first motor. The second rotating shaft is provided with a tensioner that rotates around the core in a planetary state and holds the other end of the conducting wire. The second rotating shaft rotates in the same rotational direction as the first rotating shaft and faster than the first rotating shaft, whereby the other end side of the conducting wire held by the tensioner is wound around the core to manufacture a coil component. Has been.

  In the conventional winding device, two motors, that is, a first motor for winding a conducting wire by the core and a second motor for winding the conducting wire by the core are required. In order to wind the one end side and the other end side of the conducting wire around the core, it is necessary to increase the rotation speed of the second motor relative to the first motor. For this reason, a separate control device for controlling the rotational speed is required.

  Further, the tensioner is provided so as to extend from the second rotating shaft in order to rotate around the core, but the tensioner becomes an obstacle when the core is attached to the jig. Furthermore, when the tensioner rotates due to malfunction or the like during installation, there is a risk that a hand or the like may be caught. Similarly, since the tensioner is extended and provided, it is difficult to attach other devices around the core supported by the jig.

  Therefore, an object of the present invention is to provide a highly expandable winding device that does not require a control device for tuning the rotational speed.

In order to achieve the above object, the present invention is a winding device that cross-winds a conductive wire around a core of a coil component, and the winding device rotates a core holding portion that holds the core and the core holding portion. A gear mechanism, a drive unit that drives the gear mechanism, a first wire clamper that supports one end of the conducting wire, and a rotation axis that is coaxial with the rotation axis of the core holding unit and is provided around the rotation axis of the core holding unit and is the same as the core holding unit. A second wire clamper that is rotated at a rotational speed faster than the rotational speed of the core holding portion in the rotational direction and supports the other end side of the conductive wire. The core holding part rotates and winds the conductive wire up to the core while the second wire clamper rotates and winds the conductive wire from the core to the core while laminating the conductive wires . Providing wire equipment To.

  According to such a configuration, the winding device can be driven by one drive device, for example, one motor. Therefore, it is not necessary to control the rotational speed of the drive device itself, and the control device can be omitted. Further, by interposing the gear mechanism between the driving device and the core holding part and the second wire clamper, the rotation ratio of the core holding part and the second wire clamper can be arbitrarily set. Furthermore, by supporting the conducting wire with the first wire clamper and the second wire clamper, an appropriate tension can be applied to the conducting wire when the conducting wire is wound around the core. The conductive wire can be preferably wound around the core. In addition, since the core can be held by the core holding portion only by supporting the core from one direction, it is not necessary to provide a winding device on the other side of the core, and the other side of the core is opened. State. Therefore, expandability as a winding device such as attaching various accessory devices to the other side of the core can be enhanced.

  The gear mechanism preferably includes a first gear that rotates the core holding portion and a second gear that rotates the second wire clamper, and the rotation ratio between the first gear and the second gear is preferably 1: 2. .

  According to such a configuration, when the conducting wire is wound around the core, the number of turns of the conducting wire on the one end side and the conducting wire on the other end side can be set to the same number of turns. Therefore, both ends of the conducting wire are wound evenly, and variations as coil components can be reduced.

  Moreover, it is preferable that the winding apparatus further includes a heating device that can heat the core held by the core holding unit, and the heating unit that heats the core of the heating device is disposed in the vicinity of the core holding unit.

  According to such a configuration, the core and the wound conductive wire can be heated when the conductive wire is wound. Therefore, by applying a heat-meltable adhesive or the like to the conductive wires in advance, the conductive wires that are wound and laminated can be bonded by heating simultaneously with the winding of the conductive wires. Thereby, even when the conducting wire is cut after winding the conducting wire, the wound conducting wire is not unwound from the core, so that the subsequent workability and the stability of the coil component can be improved.

  According to the winding device of the present invention, it is possible to provide a highly expandable winding device without requiring a control device for tuning the rotational speed.

  A winding device according to an embodiment of the present invention will be described with reference to FIGS. A winding apparatus 1 shown in FIG. 1 is an apparatus that manufactures coil components by a crosswise winding method. The crosswise winding method is a method in which the conductors wound around the core part of the coil component are crossed into two rows at the beginning of winding, and thereafter the two wires are wound while the conductor wires are laminated at the same time.

  The coil component manufactured by the winding device according to the present embodiment is obtained by winding a rectangular wire with a substantially rectangular cross section around a drum-shaped core, and the outer shape is a substantially cylindrical shape with a diameter of about 4 mm. FIG. 2 shows a state where the rectangular wire 32 is wound around the core 31. The core 31 is provided with a pair of flanges 31B at both ends of the core 31A (FIG. 4). A heat fusible resin is applied to the core 31A, and a rectangular wire 32 is wound thereon. One end portion 32 </ b> A and the other end portion 32 </ b> B of the flat wire 32 are maintained in a state extending in the tangential direction from the outermost layer of the coil component 30.

  As shown in FIG. 1, the winding device 1 includes a main body 2 and a flat wire supply unit 14 that supplies a flat wire 32 to the main body 2. The main body 2 has a built-in motor 3 for driving a gear mechanism described later. The output shaft 3A of the motor 3 is connected to a drive motor gear 4 (number of teeth: 60) which is a spur gear. The motor 3 is a motor that can easily control the rotation angle, such as a stepping motor. The drive motor gear 4 is disposed outside the main body 2.

  A spindle gear 5 (number of teeth: 60), which is a first gear, meshes with the drive motor gear 4, and a first intermediate gear 6 (number of teeth: 30) is further connected to the spindle gear 5, and further to the first intermediate gear 6. Is meshed with the first connecting gear 7 (number of teeth: 15). One end of a spindle shaft 5A that rotates a chuck 21 described later is coaxially connected to the spindle gear 5. A chuck 21 as a core holding portion that holds the core 31 is fixed to the other end of the spindle shaft 5A, and a revolving gear 10 (number of teeth: 60) is loosely fitted to the spindle shaft 5A. One end of a connecting shaft 7A penetrating from the lower surface to the upper surface of the main body 2 is coaxially connected to the first connecting gear 7, and the other end of the connecting shaft 7A is connected to the second connecting gear 8 ( The number of teeth: 30) is connected coaxially.

  Above the main body 2, there are provided a second intermediate gear 9 (the number of teeth: 15) that meshes with the second connecting gear 8 and the aforementioned revolving gear 10 that meshes with the second intermediate gear 9. The drive motor gear 4, the spindle gear 5, the first intermediate gear 6, the first connection gear 7, the second connection gear 8, the second intermediate gear 9 and the revolution gear 10 constitute a gear mechanism 11. When the motor 3 rotates, the drive motor gear 4 rotates counterclockwise as indicated by an arrow in FIG. The spindle gear 5 rotates in the clockwise direction following the drive motor gear 4, so that the spindle shaft 5 </ b> A also rotates together with the spindle gear 5. On the other hand, the revolution gear 10 rotates in the same clockwise direction as the spindle gear 5 via the first intermediate gear 6, the first connection gear 7, the second connection gear 8 and the second intermediate gear 9. The gear ratio of the revolution gear 10 to the spindle gear 5 is 1: 2 based on the number of teeth of each gear constituting the gear mechanism 11, and the revolution gear 10 rotates twice when the spindle gear 5 rotates once. That is, when the chuck 21 rotates once, the revolving gear 10 rotates twice in the same direction.

  As shown in FIG. 3, the chuck 21 is embedded in the upper end of the spindle shaft 5A and fixed by a pin 21B. The central axis of the chuck 21 and the rotation axis of the spindle shaft 5A are arranged so as to be coaxial. The tip of the chuck 21 forms a holding portion 21A that is divided into four in the vertical direction. A fixed gap is provided between the parts of the holding part 21 divided into four parts, and a recessed part 21a into which the collar part 31B can be inserted is formed at the center of the front end part of the holding part 21A. Further, the holding portion 21A is formed in a substantially wedge shape in which a cross section perpendicular to the rotation axis direction becomes smaller from the tip toward the spindle shaft 5A side.

  As shown in FIG. 3, a spring 23 is provided between the holding portion 21A of the chuck 21 and a portion fixed to the spindle shaft 5A. Between the spring 23 and the holding portion 21 </ b> A, an annular chuck clamp 22 is externally inserted into the chuck 21. Since the spring 23 biases the chuck clamp 22 upward, the chuck clamp 22 is pushed up toward the holding portion 21A. Since the holding portion 21A has a substantially wedge shape, and a gap is provided between each of the four divided parts, the chuck clamp 22 is pushed up to close the gap and each of the four divided parts. Are in contact with each other.

  A bearing 24 is extrapolated to the spindle shaft 5 </ b> A, and a bearing holder 10 </ b> A is fitted to the outer peripheral portion of the bearing 24. A revolving gear 10 is fixed above the bearing holder 10A. Therefore, the revolving gear 10 is freely rotatable with respect to the spindle shaft 5A and the chuck 21, and is supported by the spindle shaft 5A.

  As shown in FIG. 1, a first wire clamper 12 that holds a flat wire 32 is provided between the flat wire supply unit 14 and the revolving gear 10. The first wire clamper 12 is provided with a pair of felts 12 </ b> A, and the rectangular wire 32 is regulated so as to always maintain a fixed direction with respect to the chuck 21. Further, when the rectangular wire 32 is held by the pair of felts 12A, it is adjusted by a screw (not shown) provided on the first wire clamper 12 so that a constant pressure is applied between the pair of felts 12A. Yes. Note that the portion of the first wire clamper 12 that holds the flat wire 32 is located at the same vertical position as or the uppermost position of the holding portion 21A.

  As shown in FIG. 3, a second wire clamper 13 similar to the first wire clamper 12 is provided at a lower position on the outer periphery of the revolving gear 10, and chucks via a groove 10 a formed in the revolving gear 10. One end portion 32A of the flat wire 32 extending from 21 is held by a pair of felts 13A (FIG. 1).

  One end portion 32A of the flat wire 32 held by the second wire clamper 13 extends from the chuck 21 in a substantially horizontal direction and then is pulled out in a substantially vertical direction. A wire guide 13B is provided at a location where the wire is bent in a substantially vertical direction so that unnecessary twisting or the like is not generated in the rectangular wire 32 between the chuck 21 and the second wire clamper 13. The wire guide 13B is disposed at a position lower than the foremost position of the holding portion 21A. Further, one end portion 32A of the flat wire 32 held by the second wire clamper 13 is suspended toward the second wire clamper 13, so that the diameter of the opening on the upper surface is at least below the revolving gear 10. A recess 2 a (FIG. 1) larger than the diameter of the revolution gear 10 is formed, and the recess 2 a is also opened on the side surface in the width direction of the main body 2.

  As shown in FIG. 1, an air heater 25, which is a heating device provided with an air injection nozzle 25 </ b> A as a heating unit, is provided on the upper surface of the main body 2 obliquely above the holding unit 21 </ b> A. Further, an operation unit 15 for a main power switch of the winding device 1 and a control unit for controlling the number of rotations of the motor, the temperature of the air heater 25, and the like is provided on the front surface (front side surface in FIG. 1) of the main body 2. It has been.

  Hereinafter, the manufacturing method of the coil component 30 by the winding device 1 will be described. First, the power is turned on, air is introduced into the air heater 25, and the heater temperature is set by the operation unit 15 so that air at a predetermined temperature is ejected from the air ejection nozzle 25A. In parallel with this, a program such as the number of windings to be wound around the core 31 is selected and set from the operation unit 15. The second wire clamper 13 is programmed in advance so as to be automatically positioned at the opening position on the side surface in the width direction. Then, in a state where the winding device 1 is operable, the chuck clamp 22 is restrained in a depressed state, the flange portion 31B of the core 31 is inserted into the recess 21a, the restraint of the chuck clamp 22 is released, and the holding portion 21A The core 31 is held. In this case, since the winding device 1 has a shape in which the upper part of the chuck 21 is opened, the holding work of the core 31 can be easily performed.

  With the core 31 held by the holding portion 21A, the flat wire 32 supported by the first wire clamper 12 is pulled out from the flat wire supply portion 14 and hung on the core portion 31A without twisting. Then, the flat wire 32 is extended to the second wire clamper 13 via the wire guide 13B with the core 31A as a fulcrum without being wound around the core 31A, and is sandwiched between the pair of felts 13A of the second wire clamper 13. At this time, one end portion 32A of the flat wire 32 located between the first wire clamper 12 and the core 31 and the other end portion 32B of the flat wire 32 located between the core 31 and the second wire clamper 13 are respectively appropriate. It is wired while maintaining tension.

  The other end portion 32B hanging from the second wire clamper 13 becomes shorter as the winding operation to the winding core portion 31A proceeds, but the length before the start of winding is at least the other end portion of the winding core portion 31A. The length of the second wire clamper 13 is such that the other end 32B is held in a state where the winding of 32B is completed. Further, as shown in FIG. 3, the positional relationship between the one end portion 32A and the other end portion 32B in a state where the flat wire 32 is wired to the second wire clamper 13 is such that the one end portion 32A is located above the other end portion 32B. ing.

  In this state, the motor 3 is powered on and winding of the flat wire 32 is started. At this time, the chuck 21 and the revolving gear 10 rotate clockwise as seen from the upper side of the main body 2 as shown in FIG. The positional relationship between the one end 32A and the other end 32B around the core 31A immediately after the start of winding is as shown in FIG. 4 because the one end 32A is located above the other end 32B. The part 32A is wound on the upper side and the other end part 32B is wound on the lower side.

  Since the core 31 rotates integrally with the chuck 21 during winding, the core 31 winds up one end portion 32A around the core portion 31A as shown in FIG. On the other hand, the second wire clamper 13 provided in the revolving gear 10 rotates twice while the chuck 21 rotates once due to the gear ratio of the gear mechanism 11. While the chuck 21 makes one revolution, the wire clamper 13 makes one revolution around the chuck 21, and at this time, the other end 32B is wound around the core 31A. Therefore, even if the number of rotations of the motor 3 is not controlled, the rotation ratio between the chuck 21 and the revolving gear 10 does not deviate, and the one end 32A and the other end 32B are accurate while the chuck 21 rotates once. Each is wound around the same length.

  Further, when the one end portion 32A is wound and the other end portion 32B is wound, the wound one end portion 32A and the other end portion 32B are supplied via the first wire clamper 12 and the second wire clamper 13, respectively. The At this time, the first wire clamper 12 and the second wire clamper 13 hold the one end portion 32A and the other end portion 32B in a state where pressure is applied, respectively, and therefore, between the first wire clamper 12 and the core portion 31A. In addition, one end 32A and the other end 32B between the second wire clamper 13 and the core B31A are in tension. For this reason, it is reduced that the flat wire 32 is shifted or twisted during winding, and it is possible to wind well.

  Simultaneously with the start of the winding, high-temperature air is injected from the air injection nozzle 25A, and the core 31 and the rectangular wire 32 are heated. Since the heat-sealable resin is applied to the flat wire 32, the flat wire 32 melted and wound by heating is bonded to the interlayer.

  Then, after a predetermined number of windings programmed in advance, the driving of the motor 3 is stopped, and the ejection of air from the air heater 25 is also stopped. At this time, as shown in FIG. 6, the coil component 30 is formed with two upper and lower coils, and one end 32 </ b> A and the other end 32 </ b> B extend from the outermost layer.

  Thereafter, the one end portion 32A is cut and the other end portion 32B held by the second wire clamper 13 is removed. In this case, the flat wire 32 is heated and wound, and the layers wound together are bonded to each other. Therefore, the wound flat wire 32 cannot be unwound. Then, the core 31 is removed from the holding portion 21A, and the one end portion 32A and the other end portion 32B are cut to a predetermined length, thereby completing the coil component 30 shown in FIG.

  In the present embodiment, a rectangular wire is used. However, the present invention is not limited to this. For example, as shown in FIG. 7, a coil component 130 using ordinary conducting wires 132A and 132B having a circular cross section can be wound in the same manner. is there. Moreover, in the winding apparatus 1 of this Embodiment, since the upper direction of the revolution gear 10 is the open shape, not only the air heater 25 but the wire cutting mechanism which cuts the wound conducting wire, for example, It is also possible to attach a core automatic supply device or the like that supplies the core through the holding portion 21A secondary path.

  In the present embodiment, the gear ratio of the gear mechanism 11 is set so that the number of turns on one end side and the other end side of the wound winding is the same. However, the present invention is not limited to this. It is also possible to set various turns by changing the intermediate gear 6 and the first connecting gear 7 to other gears having different numbers of teeth. In addition, when winding a conducting wire, the core does not necessarily need a collar, but after winding only on the core part separate from the collar, the collar is joined to produce a coil component. Also good.

The perspective perspective view of the coil | winding apparatus concerning embodiment of this invention. The perspective view of the coil components manufactured with the coil | winding apparatus concerning embodiment of this invention. The fragmentary detail view of the core holding part vicinity of the winding device according to the embodiment of the present invention. The fragmentary perspective view at the time of winding around the core of the winding apparatus concerning embodiment of this invention. The horizontal direction sectional view of the core of the winding device concerning an embodiment of the invention. The vertical direction sectional view of the core of the winding device concerning an embodiment of the invention. The vertical direction sectional view of the core concerning other examples of the winding device concerning an embodiment of the invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Winding apparatus 2 Main-body part 2a Concavity 3 Motor 3A Output shaft 4 Drive motor gear 5 Spindle gear 5A Spindle shaft 6 First intermediate gear 7 First connection gear 7A Connection shaft 8 Second connection gear 9 Second intermediate gear 10 Revolution gear 10A Bearing holder 10a Groove 11 Gear mechanism 12 First wire clamper 12A Felt 13 Second wire clamper 13A Felt 13B Wire guide 14 Flat wire supply part 15 Operation part 21 Chuck 21A Holding part 21B Pin 21a Recess 22 Chuck clamp 23 Spring 24 Bearing 25 Air heater 25A Air outlet 30 Coil component 31 Core 31A Winding core portion 31B Hook 32 Flat wire 32A One end 32B The other end

Claims (3)

A winding device for crosswise winding a conductive wire around a core of a coil component,
The winding device includes a core holding unit that holds the core;
A gear mechanism for rotating the core holding part;
A drive unit for driving the gear mechanism;
A first wire clamper that supports one end of the conducting wire;
Provided around a rotation axis coaxial with the rotation axis of the core holding part, and rotated by the gear mechanism in the same rotation direction as the core holding part at a rotation speed faster than the rotation speed of the core holding part, A second wire clamper that supports the side ,
In a state where the conductor is hung on the core, the core holding portion rotates and winds the conductor from the first wire clamper to the core, and the core to the second wire clamper. A winding device , wherein the second wire clamper rotates and winds the conductive wire around the core, and the conductive wire is wound around the core while being laminated .   The gear mechanism includes a first gear that rotates the core holding portion and a second gear that rotates the second wire clamper, and a rotation ratio of the first gear to the second gear is 1: 2. The winding device according to claim 1.   The winding device further includes a heating device capable of heating the core held by the core holding unit, and the heating unit for heating the core of the heating device is disposed in the vicinity of the core holding unit. The winding device according to claim 1, wherein the winding device is characterized by the following.

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