JP6401564B2 - Noise filter and manufacturing method thereof - Google Patents

Description

  The present invention relates to a noise filter and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, as a building becomes higher-rise and larger, a ground wire is installed in a building over a long distance, so that high-frequency noise easily enters the ground wire. In such a situation, the high frequency noise that has entered the ground wire becomes a resonance state and the amplitude increases, which may cause the electronic device to malfunction or be damaged. Therefore, a noise filter for grounding wires that is inserted into the grounding wire of electrical equipment and suppresses high-frequency noise flowing through the grounding wire has been proposed (see Patent Document 1).

JP 08-214449 A

  In order to suppress high frequency noise, it is common to increase the impedance Z of the noise filter. Here, the impedance Z is a resistance value with respect to an alternating current, and the larger the impedance Z, the less the alternating current flows. The impedance Z of the noise filter is expressed as [Equation 1] below. In [Expression 1], f is a frequency, and L is an inductance of the coil.

    [Formula 1] Z = 2πf × L

As shown in [Equation 1], the impedance Z of the noise filter is small for a component having a low frequency f and large for a component having a high frequency f. For this reason, when a noise filter is inserted into a ground line into which high-frequency noise is likely to invade, a commercial frequency component having a low frequency f is not disturbed, and only a high-frequency noise component having a high frequency f can be attenuated. That is, only the high-frequency noise current can be suppressed without suppressing the commercial-frequency ground fault current.

Further, the magnitude of the impedance Z of the noise filter is directly proportional to the inductance L of the coil, and as a means for improving the suppression characteristic of the high frequency noise current, increasing the inductance L of the coil can be mentioned. The inductance L of the coil is expressed as [Equation 2] below. In [Expression 2], μ is the magnetic permeability of the coil core, N is the number of turns of the coil, L ₁ is the length of the coil, and S is the cross-sectional area of the coil.

[Formula 2] L = μ × N ² × S / L ₁

That is, as a method for increasing the inductance L of the coil, the following (i) to (iii) are performed. That is, (i) the coil cross-sectional area S is increased by increasing the coil diameter (winding diameter). (Ii) Increasing the number of turns N by increasing the number of turns of the coil. (Iii) to shorten the coil, shortening the length L _1.

  In recent years, with the spread of inverter equipment, leakage current (high-frequency noise current) due to operation of the inverter has caused electromagnetic interference. In response to such a background, the noise filter inserted into the ground wire of the electric equipment cannot be handled by the conventional noise filter. Therefore, a high-performance and compact noise filter that can be replaced in the same way in a place where a noise filter is already installed and that has a characteristic that can reliably suppress high-frequency noise current from the inverter. It is desired. That is, the noise filter is required to have a characteristic that can suppress a leakage current flowing in the ground line by the operation of the inverter and be small.

However, the noise filter is designed so that the high frequency noise current from the inverter can be suppressed while the noise filter is not damaged by the ground fault current of the commercial frequency and the ground fault current is not absorbed and reliably flows to the ground. In order to increase the impedance Z of the wire, for example, a thick and difficult-to-bend insulated wire of 100 SQ (mm ² ) is used, and the number of times this insulated wire is wound around the core (magnetic material) is increased, or the number of cores is increased. For example, there are factors that hinder the workability in coil manufacture and the miniaturization of the noise filter, and the miniaturization has a limit.

  In addition, since a cut core (divided core) was used in a conventional noise filter, it was very easy to wind an insulated wire around the core. The increase in the number of cores, the increase in the number of turns of the coil, the increase in the coil diameter, etc. cannot be avoided, and there was a limit to the reduction in size. Therefore, by changing the core to be used from a cut core (divided core) to a non-divided closed ring ring core, high noise noise suppression performance can be expected, but coil winding (assembly) around the ring core is difficult. There was a drawback of becoming.

  Therefore, an object of the present invention is to provide a compact noise filter that can reliably suppress high-frequency noise current flowing through a grounding wire.

A noise filter according to the present invention is a noise filter that is inserted into a ground wire of an electric facility and suppresses a noise current flowing through the ground wire. The coil member is formed of an insulated wire spirally wound, and the coil member. A plurality of ring-shaped cores that are loosely fitted to the ring-shaped core, the ring-shaped cores are formed in a non-divided closed ring shape, and the spiral insulated wire is inserted into the hole of the ring-shaped core. In addition, the insulated wires are bound and fixed spirally by a plurality of band members, and the coil member and the ring-shaped core are connected to form an integrated coil unit. These are housed in a case member composed of a box-shaped main body and a lid, and are fixed to the inner surface of the box-shaped main body by a band plate-like pressing member.
In addition, in a noise filter that is inserted into a ground wire of an electrical facility and suppresses a noise current flowing through the ground wire, a coil member made of an insulated wire spirally wound, and loosely fitted to the coil member. A ring-shaped core inserted into the ring-shaped core, the ring-shaped core is formed in a non-divided closed ring shape, the spiral insulated wire is inserted into the hole of the ring-shaped core, and the ring-shaped core The coil member is expanded along the circumferential direction into a fan shape to form an integrated coil unit, and the coil unit is housed in a case member including a box-shaped main body and a lid, and a plurality of bands The member is fixed to the columnar fixing member provided on the lid and the inner surface of the lid.

In addition, the method for manufacturing a noise filter according to the present invention cuts an insulated wire having a conductor stranded wire covered with an insulating layer into a predetermined length, and fixes one end of the insulated wire to a cylindrical mandrel. The insulated wire is wound a plurality of times around the outer periphery of the mandrel, the one end is opened, the insulated wire spirally formed by the winding is removed from the mandrel, a coil member is formed, The axial dimension of the coil member is extended, the interval between the insulated wires is increased to a predetermined pitch, and the insulated wires formed in a spiral shape are inserted into holes of a plurality of ring-shaped cores from one end side, The ring-shaped core is fitted into the coil member in a loose fit, the axial dimension of the coil member is shortened, the spiral insulated wires are bundled by a plurality of band members, and the coil member and the ring-shaped Are connected to each other to form an integral coil unit, and the coil unit is fixed to the inner surface of the box-shaped main body of the case member by a band plate-like pressing member, and one end and the other end of the insulated wire are A projecting shape is formed from the box-shaped main body, and a lid is attached to the box-shaped main body to cover the case, and the coil unit is housed in the case member.
In addition, an insulated electric wire having a conductor stranded wire covered with an insulating layer is cut into a predetermined length, one end of the insulated electric wire is fixed to a cylindrical mandrel, and the insulated electric wire is attached to the outer periphery of the mandrel. Winding multiple times, opening the one end, removing the insulated wire spirally formed by the winding from the mandrel, forming a coil member, extending the axial dimension of the coil member, The interval between the insulated wires is expanded to a predetermined pitch, the insulated wire having a spiral shape is inserted into the hole of the ring-shaped core from one end side, and the ring-shaped core is fitted loosely into the coil member, The coil member is expanded along the circumferential direction of the ring-shaped core to form a fan, forming an integrated coil unit, and the coil unit is provided with a columnar fixing member provided on the lid of the case member by a band member. Secured to the inner surface of the lid, and applying a cover attached to the box-shaped body of the lid is for housing the coil unit in the case member as protrude to one end and the other end of the insulated wire.

  According to the noise filter and the manufacturing method thereof of the present invention, the impedance can be increased without increasing the size of the coil member and the ring-shaped core, and the noise current suppression characteristics can be enhanced. Therefore, it is possible to reliably suppress high-frequency noise current flowing through the ground line without hindering commercial-frequency ground fault current, and to achieve downsizing. Further, it can be replaced (replaced) in the same manner as the installation location of the existing noise filter. A coil unit composed of a coil member and a ring-shaped core can be housed in a case member and fixed in place, and even when the coil unit generates heat during use, the influence on peripheral devices can be suppressed. Further, it is possible to prevent the coil member from being deformed at the time of carrying or carrying work, and to prevent the case member from being damaged at the time of carrying. In spite of the structure using the non-divided closed ring-shaped core, the coil member can be easily wound (assembled) around the ring-shaped core, and the workability can be improved.

It is the rear view which showed one Embodiment of this invention in the partial cross section. It is the top view which showed one Embodiment of this invention in the partial cross section. It is the front view which showed other embodiment of this invention in the partial cross section. It is the side view which showed other embodiment of this invention in the partial cross section. It is explanatory drawing which shows the 1st process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 2nd process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 3rd process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 4th process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 5th process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 6th process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 7th process which concerns on the manufacturing method of the noise filter of this invention. It is sectional drawing for description which shows the 8th process which concerns on the manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 1st process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 2nd process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 3rd process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 4th process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 5th process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 6th process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 7th process which concerns on the other manufacturing method of the noise filter of this invention. It is explanatory drawing which shows the 8th process which concerns on the other manufacturing method of the noise filter of this invention.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
As shown in FIGS. 1 and 2, the noise filter of the present invention is a noise filter (for grounding wire) that suppresses a noise current flowing through the grounding wire, and includes an insulated wire 20 wound in a spiral shape. The coil member 5 is provided with a plurality of ring-shaped cores 6 and 6, and the coil member 5 and the plurality of ring-shaped cores 6 and 6 are connected and integrated to form a coil unit 10.
The coil member 5 is formed in a spiral shape by being wound around the outer periphery of a columnar mandrel 30 (see FIG. 7) described later (in the right-handed direction), and has a substantially uniform coil diameter. The insulated wires 20 are bound and fixed in a spiral shape excluding both end portions 25 and 26 by the plurality of band members 8, and the adjacent insulated wires 20 are in contact with each other without leaving a gap. The band member 8 binds the insulated wires 20 at 2 or more and 10 or less, preferably 4 or more and 6 or less, and is arranged at equal intervals in the winding direction of the coil member 5. By binding the helical insulated wires 20 in this way, variations in impedance are suppressed. Both end portions 25 and 26 of the insulated wire 20 are extended from the spiral insulated wire 20 in the same straight line in parallel and opposite to the coil axis direction. Terminals T and T for connecting to both ends 25 and 26 are connected to a ground wire of the electric equipment.

As the insulated wire 20, a conductor stranded wire 21 whose outer layer is covered with an insulating layer 22 is used. The conductor stranded wire 21 is formed by twisting a plurality of conductor wires made of copper or a copper alloy. For example, a conductor wire made of tough pitch copper is preferably used. One conductor wire has a tensile strength of 300 MPa or less, and more preferably an annealed copper wire of 245 MPa to 275 MPa. Alternatively, a conductor wire having a tensile strength exceeding 300 MPa may be used, specifically, a hard copper wire of 330 MPa to 460 MPa. The outer periphery of the conductor wire may be appropriately plated. For example, corrosion resistance is improved by performing tin plating. The cross-sectional area of the conductor twisted wire 21 may be appropriately set depending on the magnitude of the current flowing through the ground wire of the electrical equipment, and is set to 3.5 mm ² or more and 200 mm ² or less, more preferably 5.5 mm ² or more and 100 mm ² or less. And The twist pitch of the conductor twisted wire 21 is 15 mm or more and 400 mm or less, and more preferably 30 mm or more and 220 mm or less. For the insulating layer 22, for example, PVC (polyvinyl chloride resin composition), non-lead PVC, PE, cross-linked polyethylene, a non-halogen resin composition containing no halogen element, a rubber composition, or the like is used. The thickness of the insulating layer 22 is 0.8 mm or more and 2.8 mm or less, preferably 1.0 mm or more and 2.0 mm or less. If the thickness of the insulating layer 22 is less than the lower limit, sufficient insulation cannot be maintained, and scratch resistance may be reduced. On the other hand, if the upper limit value is exceeded, formation of the insulated wire 20 becomes extremely difficult. The outer diameter of the insulated wire 20 is determined by the outer diameter of the conductor twisted wire 21 to be used and the thickness of the insulating layer 22, but is set to 2.8 mm to 35 mm.

  The ring-shaped core 6 is formed in a non-divided closed ring and is fitted into the coil member 5 in a loose fit. That is, the ring-shaped core 6 is not a structure in which the divided cores are combined, and there is no interface, so that high performance in suppressing noise current can be achieved. The shape of the ring-shaped core 6 is a rectangular shape when viewed from the front. The hole 6A is formed in a rectangular shape. Insulated electric wires 20 having a spiral shape are inserted into the holes 6A and 6A of the ring-shaped cores 6 and 6, respectively. The use of the non-divided closed annular core 6 makes it difficult to wind the insulated wire 20 around the ring-shaped core 6. Is passed through the hole 6A of the ring-shaped core 6 one by one, so that the coil member 5 can be easily fitted into the core 6 (non-divided closed ring). In addition, it is preferable that the corner | angular part of the ring-shaped core 6 is chamfered so that the insulated wire 20 may not be damaged at the time of insertion. Although the number of the ring-shaped cores 6 is two in the illustrated example, it may be more than two or may be one. In consideration of downsizing, it is preferable that the number of the ring-shaped cores 6 be two or less. A plurality of (two) ring-shaped cores 6, 6 are loosely fitted into the coil member 5, and the ring-shaped cores 6, 6 are connected (bundled) by a plurality of band members 8, and The coil member 5 and a plurality (two) of ring-shaped cores 6 and 6 are integrated. By integrating the coil member 5 and the plurality of ring-shaped cores 6 and 6 in this way, variation in impedance is suppressed, and the ring-shaped cores 6 and 6 are fixed, so that the case member 3 described later can be connected. Collisions are prevented.

A coil unit 10 including a coil member 5 and a plurality of ring-shaped cores 6 and 6 is housed in the case member 3.
The case member 3 includes a box-shaped main body 3A having an opening on the back surface and a lid 3B that covers the opening of the box-shaped main body 3A, and is formed of a synthetic resin such as PVC. As shown in FIGS. 2 and 12, a pair of upper and lower fixing convex portions 33, 33 are provided on the inner surface of the front wall portion of the box-shaped main body 3 </ b> A, and a concave portion 34 is formed between the convex portions 33, 33. Yes. In the coil unit 10, the coil member 5 is fitted in the recess 34, and is fixed to the inner surface of the box-type main body 3 </ b> A by the strip plate-like pressing member 4. The convex portions 33 and 33 have screw holes, and the band plate-like pressing member 4 is bridged over the convex portions 33 and 33 and fixed by the screw members. By fixing the coil unit 10 to the inner surface of the box-type main body 3A, it is possible to prevent the coil unit 10 from colliding with the inner surface of the box-type main body 3A and to deform the coil member 5 at the time of transporting and mounting operations. The case member 3 is prevented from being damaged by the collision of the ring-shaped cores 6 and 6. U-shaped cutouts 35 and 35 are formed in the ceiling wall and bottom wall of the case member 3 (box-shaped main body 3A), and both ends 25 and 26 of the insulated wire 20 are fitted into the cutouts 35 and 35. Then, the two end portions 25 and 26 are accurately positioned by protruding outward from the case member 3. Both end portions 25 and 26 are collinear and extend in opposite directions, and are fitted and held in the cutout portions 35 and 35 of the case member 3 so that the coil unit 10 is aligned along the inner surface of the box-shaped main body 3A. Can be stored in a small space.

3 and 4 show another embodiment of the present invention.
3 and FIG. 4, the coil member 5 which consists of the insulated wire 20 wound helically and the one ring-shaped core 6 are provided. The ring-shaped core 6 has an annular shape when viewed from the front. The hole 6A is formed in a circular shape. The ring-shaped core 6 is formed in a non-divided closed ring and is not a structure in which the divided ones are combined, and since there is no interface, it is possible to improve the performance of noise current suppression. The spiral insulated wire 20 is inserted into the hole 6 </ b> A of the ring-shaped core 6, the ring-shaped core 6 is loosely fitted into the coil member 5, and the coil member 5 extends along the circumferential direction of the ring-shaped core 6. Is expanded into a fan shape, and an integrated coil unit 10 is formed.

Insulated wire 20, the cross-sectional area of the conductor twisted wire 21 is preferably used is relatively thin in 5.5mm ² ~14mm ^2. The spiral insulated wire 20 is fitted into the annular ring-shaped core 6, the adjacent insulated wires 20 are spread at substantially equal intervals, and the coil member 5 is fan-shaped. Since the coil member 5 is formed in a fan shape, the number of turns can be increased when the coil member 5 is wound around and fitted into the annular ring-shaped core 6, and the coil member 5 can be spread in a well-balanced manner, thereby reducing the impedance variation.

3 and 4, the coil unit 10 is housed in a case member 3 composed of a box-shaped main body 3A and a lid 3B, and a columnar fixing member 7 provided on the lid 3B by a plurality of band members 8. And fixed to the inner surface of the lid 3B.
A cylindrical fixing member 7 is integrally formed on the lid 3B, and a plurality of band receiving portions 18, 18, and 18 that can lock the band member 8 are provided on the inner surface. By fixing the coil unit 10 to the inner surface of the fixing member 7 and the lid 3B, it is possible to prevent the coil unit 10 from colliding with the inner surface of the box-type main body 3A and deforming the coil member 5 at the time of carrying or carrying work. In addition, the case member 3 is prevented from being damaged by the collision of the ring-shaped cores 6 and 6. U-shaped cutouts 35 and 35 are formed in the ceiling wall and bottom wall of the case member 3 (box-shaped main body 3A), and both ends 25 and 26 of the insulated wire 20 are fitted into the cutouts 35 and 35. Then, it projects from the case member 3 to the outside and is positioned accurately.

A method for manufacturing the above-described noise filter of the present invention will be described with reference to FIGS.
In the first step shown in FIG. 5, the insulated wire 20 for forming the coil member 5 is cut into a predetermined length L _0.
Next, in the second step shown in FIG. 6, one end portion 25 of the insulated wire 20 is fixed along the axial direction of the cylindrical mandrel 30. The one end portion 25 of the insulated wire 20 is sandwiched and fixed by a vise fixed on one end side of the mandrel 30.

In the third step shown in FIG. 7, the insulated wire 20 is wound around the outer periphery of the mandrel 30 a plurality of times.
The number of windings of the insulated wire 20 around the mandrel 30 is one or two times more than the number of turns N of the insulated wire 20 fitted in a hole 6A of the ring-shaped core 6 described later (spiral) (N + 1, or N + 2) is preferred. Specifically, when the coil member 5 is set to 4 to 6 turns, in this third step, the insulated wire 20 is wound around the mandrel 30 5 to 8 times. At this time, the adjacent insulated wires 20 are wound closely without leaving a gap.

Next, in a fourth step shown in FIG. 8, the one end portion 25 is opened, and the insulated wire 20 that is spirally formed by winding is removed from the mandrel 30, thereby forming the coil member 5.
The coil member 5 is formed in a substantially cylindrical shape having a uniform coil diameter. Coil member 5, the repulsive force due to elastic deformation at the time of winding the insulated wire 20 in a spiral, by a so-called spring-back, the outside diameter D of the outer diameter D ₃ of the coil member 5 is open before the helical insulated wire 20 ₂ (see FIG. 7). That is, before At a third step of, considering that the springback, than the inner diameter of the desired coil member 5, it is preferable to use a mandrel 30 of smaller outer diameter D _1.
The outer diameter _{D 1} of the mandrel 30, the relationship between the outer diameter _{D 3} of the coil member 5, the conductor stranded 21 of insulated wire 20, twisting the tensile strength of the one conductor line is annealed copper wire of 245MPa~275MPa combined If 0.45 × D ₃ ≦ D ₁ ≦ 0.80 × D ₃ , the desired coil member 5 can be formed with an error within ± 5 mm. For example, the insulated wire 20 in the cross-sectional area of 38mm ² ~60mm ² conductors stranded wire 21, when the outer diameter _{D 3} to be molded into the coil member 5 of _{90mm~100mm, 0.65 × D 3 ≦ D} 1 ≦ and 0.73 × _{D 3,} specifically, it is preferable to set the outer diameter _{D 1} of the mandrel 30 to 65 mm. Also, if the cross-sectional area of the conductor twisted wire 21 is an insulated wire 20 of 100 mm ^2, the outer diameter _{D 3} to be molded into the coil member 5 of _{125mm~135mm, 0.67 × D 3 ≦ D} 1 ≦ 0.72 × and _{D 3,} specifically, it is preferable to set the outer diameter _{D 1} of the mandrel 30 to 90 mm.

In the fifth step shown in FIG. 9, it extends the axial dimension of the coil member 5, to expand the spacing between the insulated wire 20 in a predetermined pitch P _2. As shown in FIGS. 8 to 9, the pitch of the insulated wires 20 is increased from P ₁ to P ₂ in preparation for facilitating fitting of the ring-shaped core 6 into the coil member 5 in the next step. The coil member 5 is arranged so that the pitch P ₂ of the insulated wires 20 is 1.5 × W ≦ P ₂ ≦ 3.0 × W with respect to the width dimension W (see FIG. 10) of the ring-shaped core 6 described later. Elongate. Pitch P ₂ of the insulated wire 20 is, if less than 1.5 times the width W, the ring-shaped core 6 there is a possibility of damaging the outer surface in contact with the insulated wire 20. If the width W is larger than 3.0 times, the spiral insulated wire 20 cannot be inserted into the hole 6A of the ring-shaped core 6 with a sufficient number of turns. Further, before proceeding from the fifth step to the sixth step, a predetermined length portion bent in an L shape is cut from the one end portion 25 of the insulated wire 20. This is also a preparation for the next step, and is to facilitate insertion of the spiral insulated wire 20 into the hole 6A of the ring-shaped core 6 from the one end 25 side.

  Next, in the sixth step shown in FIG. 10, the spiral insulated wire 20 is inserted from the one end 25 side into the holes 6 </ b> A and 6 </ b> A of the plurality of ring-shaped cores 6 and 6, and the coil member 5 is inserted. One turn is inserted into two ring-shaped cores 6 and 6. Here, when the corner of the ring-shaped core 6 is chamfered, the insulated wire 20 is not damaged. Although not shown in the drawings as another means for not damaging the insulated wire 20, a tape for preventing damage may be applied in advance to the outer surface of the ring-shaped core 6 and fitted into the coil member 5, and then the tape is removed. . Alternatively, paint may be applied to the outer surface of the ring-shaped core 6 to reduce the friction, and the above-described means for preventing damage to the insulated wire 20 may be used in combination. Thus, a predetermined number of coil turns of the coil member 5 is fitted into the hole portions 6A and 6A of the two ring-shaped cores 6 and 6, and the spiral insulated wire 20 is inserted into the hole portions of the ring-shaped cores 6 and 6. 6A and 6A are inserted in a loose fit.

As shown in FIG. 11, in the seventh step, the axial direction dimension of the coil member 5 is shortened, and the plurality of band members 8 are loosely fitted into the holes 6 </ b> A and 6 </ b> A of the ring-shaped cores 6 and 6. The inserted helical insulated wire 20 is bound. The coil member 5 may be bound so that adjacent spiral insulated wires 20 are in contact with each other and are closely aligned. Further, the coil member 5 and the ring-shaped cores 6 and 6 are connected by a plurality of band members 8 to form an integral coil unit 10. After the coil unit 10 is formed, one end 25 and the other end 26 of the insulated wire 20 are processed into a straight line, and terminals T and T (see FIG. 1) are attached if necessary. The terminals T and T may be attached after being stored in the case member 3. The insulated wire 20 is formed so that the outer peripheral edge of the spiral portion, the one end 25 and the other end 26 are in the same straight line.
Next, in the eighth step shown in FIG. 12, the coil unit 10 is fixed to the inner surface of the box-shaped main body 3 </ b> A of the case member 3 by the band plate-like pressing member 4. As shown in FIGS. 1 and 2, one end portion 25 and the other end portion 26 of the insulated wire 20 are projected from the box-type main body 3A, and the lid body 3B is attached to the box-type main body 3A to cover the case member 3. The coil unit 10 is housed in the container.

Next, another method for manufacturing the noise filter of the present invention will be described with reference to FIGS.
In the first step shown in FIG. 13, the insulated wire 20 for forming the coil member 5 is cut into a predetermined length L _0.
Next, in the second step shown in FIG. 14, the one end 25 of the insulated wire 20 is fixed along the axial direction of the cylindrical mandrel 30. The one end portion 25 of the insulated wire 20 is sandwiched and fixed by a vise fixed on one end side of the mandrel 30.

In the third step shown in FIG. 15, the insulated wire 20 is wound around the outer periphery of the mandrel 30 a plurality of times.
The number of windings of the insulated wire 20 around the mandrel 30 is preferably three times (N + 3) more than the number of turns N of the insulated wire 20 fitted in a hole 6A of the ring-shaped core 6 described later (spiral). . Specifically, when the coil member 5 is set to 7 to 10 turns, in this third step, the insulated wire 20 is wound around the mandrel 30 10 to 13 times. At this time, the adjacent insulated wires 20 are wound closely without leaving a gap.

Next, in a fourth step shown in FIG. 16, the one end portion 25 is opened, and the insulated wire 20 that is spirally formed by winding is removed from the mandrel 30 to form the coil member 5.
Coil member 5, by the spring-back, its outer diameter D _3, greater than the outer diameter D ₂ of the open front of the helical insulated wire 20 _(see FIG. 7). That is, before At a third step of, considering that the springback, than the inner diameter of the desired coil member 5, it is preferable to use a mandrel 30 of smaller outer diameter D _1.
The outer diameter _{D 1} of the mandrel 30, the relationship between the outer diameter _{D 3} of the coil member 5, for example, tensile strength of the conductor stranded 21 one conductor line is constituted by the twisting of the annealed copper wire of 245MPa~275MPa be those with, if the cross-sectional area of the insulated wire 20 of 5.5mm ² ~14mm ^2, the outer diameter _{D 3} to be molded into the coil member 5 of 42mm~55mm, 0.490 × _{D 3} ≦ _{D If 1} ≦ 0.642 × D ₃ and specifically, the outer diameter D ₁ of the mandrel 30 is set to 27 mm, the desired coil member 5 can be formed with an error within ± 5 mm.

In the fifth step shown in FIG. 17, it decompresses the axial dimension of the coil member 5, to expand the spacing between the insulated wire 20 in a predetermined pitch P _2. As shown in FIGS. 16 to 17, the pitch of the insulated wires 20 is increased from P ₁ to P ₂ in preparation for easily fitting the ring-shaped core 6 into the coil member 5 in the next step. The coil member 5 is arranged so that the pitch P ₂ of the insulated wires 20 is 1.5 × W ≦ P ₂ ≦ 3.0 × W with respect to the width dimension W (see FIG. 18) of the ring-shaped core 6 described later. Elongate. Pitch P ₂ of the insulated wire 20 is, if less than 1.5 times the width W, the ring-shaped core 6 there is a possibility of damaging the outer surface in contact with the insulated wire 20. If the width W is larger than 3.0 times, the spiral insulated wire 20 cannot be inserted into the hole 6A of the ring-shaped core 6 with a sufficient number of turns. Further, before proceeding from the fifth step to the sixth step, a predetermined length portion bent in an L shape is cut from the one end portion 25 of the insulated wire 20. This is also a preparation for the next step, and is to facilitate insertion of the spiral insulated wire 20 into the hole 6A of the ring-shaped core 6 from the one end 25 side.

  Next, in the sixth step shown in FIG. 18, the spiral insulated wire 20 is inserted into the hole 6A of the ring-shaped core 6 from the one end 25 side, and the coil member 5 is wound by two rings. Fit into the cores 6 and 6. Finally, the predetermined number of coil turns of the coil member 5 is inserted into the hole 6A of the ring-shaped core 6 and is fitted in a loose fit. The ring-shaped core 6 is provided with a means for preventing damage such as chamfering the corners or coating the outer surface with resin.

As shown in FIG. 19, in the seventh step, the coil member 5 is expanded along the circumferential direction of the ring-shaped core 6 to form a fan shape, and the integrated coil unit 10 is formed. When the coil unit 10 is formed, the one end 25 and the other end 26 of the insulated wire 20 are processed into a straight line, and terminals (not shown) are attached if necessary. The insulated wire 20 is formed so that the outer peripheral edge of the spiral portion, the one end 25 and the other end 26 are in the same straight line.
Next, in the eighth step shown in FIG. 20, the coil unit 10 is fixed to the inner surface of the cylindrical fixing member 7 provided on the lid 3 </ b> B of the case member 3 and the lid 3 </ b> B by the band member 8. As shown in FIGS. 3 and 4, the lid 3B to which the coil unit 10 is fixed is attached to the box-type main body 3A and covered, and the one end 25 and the other end 26 of the insulated wire 20 are projected to form a case. The coil unit 10 is accommodated in the member 3.

  The present invention can be changed in design. For example, the shape of the case member 3 can be further changed so that the coil unit 10 can be held in a stable posture without rattling.

  As described above, the noise filter according to the present invention is a coil composed of the insulated wire 20 spirally wound in the noise filter that is inserted into the ground wire of the electrical equipment and suppresses the noise current flowing through the ground wire. Member 5 and a plurality of ring-shaped cores 6, 6 fitted loosely into coil member 5, ring-shaped core 6 is formed in a non-divided closed ring, and spiral insulated wire 20 is The insulated wires 20 are spirally bound and fixed by the plurality of band members 8 and the coil member 5 and the ring-shaped cores 6 and 6 are connected by the plurality of band members 8 inserted through the hole portions 6A and 6A of the ring-shaped cores 6 and 6. Thus, an integrated coil unit 10 is formed. Further, the coil unit 10 is housed in a case member 3 composed of a box-shaped main body 3A and a lid 3B, and is formed on the inner surface of the box-shaped main body 3A by a band plate-shaped pressing member 4. Because it is fixed Yl member 5 and the ring-shaped core 6, 6 without increasing the size of, it is possible to increase the impedance, it can be high performance characteristics of the noise current suppression. Therefore, it is possible to reliably suppress high-frequency noise current flowing through the grounding line without hindering commercial-frequency ground fault current, and to realize downsizing and compact design. It can be replaced in the same way as the installation location of the existing noise filter. The coil unit 10 composed of the coil member 5 and the ring-shaped cores 6 and 6 can be housed in the case member 3 and fixed at a fixed position, and even when the coil unit 10 generates heat during use, it has an influence on peripheral devices. Can be suppressed. Further, it is possible to prevent the coil member 5 from being deformed at the time of transportation and attachment work, and it is possible to prevent the case member 3 from being damaged during transportation. In spite of the structure using the non-divided closed ring-shaped core 6, the coil member 5 can be easily wound (assembled) around the ring-shaped core 6, and workability can be improved.

  In addition, in a noise filter that is inserted into a ground wire of an electric facility and suppresses a noise current flowing through the ground wire, the coil member 5 is formed of an insulated wire 20 wound in a spiral shape, and is loosely fitted to the coil member 5. And the ring-shaped core 6 is formed in a non-divided closed ring, the spiral insulated wire 20 is inserted through the hole 6A of the ring-shaped core 6, and the ring shape The coil member 5 is expanded along the circumferential direction of the core 6 into a fan shape to form an integral coil unit 10, and the coil unit 10 further includes a case member 3 composed of a box-shaped main body 3A and a lid 3B. And fixed to the inner surface of the cylindrical fixing member 7 and the lid 3B provided on the lid 3B by a plurality of band members 8, so that the coil member 5 and the ring-shaped core 6 are not enlarged. , Impedance Can be increased, it can be high performance characteristics of the noise current suppression. Therefore, it is possible to reliably suppress high-frequency noise current flowing through the grounding line without hindering commercial-frequency ground fault current, and to realize downsizing and compact design. It can be replaced in the same way as the installation location of the existing noise filter. The number of turns of the coil member 5 can be increased, and the coil member 5 can be expanded in a well-balanced manner, thereby suppressing variations in impedance. The coil unit 10 including the coil member 5 and the ring-shaped core 6 can be housed in the case member 3 and fixed in place, and even when the coil unit 10 generates heat during use, the influence on peripheral devices can be suppressed. . Further, it is possible to prevent the coil member 5 from being deformed at the time of transportation and attachment work, and it is possible to prevent the case member 3 from being damaged during transportation. In spite of the structure using the non-divided closed ring-shaped core 6, the coil member 5 can be easily wound (assembled) around the ring-shaped core 6, and workability can be improved.

In addition, the method for manufacturing a noise filter according to the present invention cuts the insulated wire 20 in which the conductor twisted wire 21 is covered with the insulating layer 22 into a predetermined length L _0, and connects one end portion 25 of the insulated wire 20 to The insulated electric wire 20 is fixed to the cylindrical mandrel 30, the insulated wire 20 is wound around the outer periphery of the mandrel 30 a plurality of times, the one end 25 is opened, and the insulated electric wire 20 formed into a spiral shape by winding is removed from the mandrel 30. forming a member 5, extending the axial dimension of the coil member 5, to expand the interval between the insulated wire 20 in a predetermined pitch P _2, a plurality of ring insulated wire 20 that forms a spiral from one end 25 side The ring-shaped cores 6 and 6 are inserted into the coil members 5 so as to be loosely fitted, and the axial dimension of the coil members 5 is shortened by the plurality of band members 8. , Spiral insulated wire 20 In addition to binding, the coil member 5 and the ring-shaped cores 6 and 6 are connected to form an integral coil unit 10. The coil unit 10 is fixed to the case member 3 by being fixed to the inner surface, with one end 25 and the other end 26 of the insulated wire 20 projecting from the box-shaped main body 3A, and the lid 3B attached to the box-shaped main body 3A. Since it is housed, the coil member 5 having a uniform coil diameter can be wound around and fitted into the ring-shaped core 6 even in the structure using the non-divided closed ring-shaped core 6. Work becomes easy and workability can be improved. The noise current suppression characteristics can be stably improved. By storing the coil unit 10 in the case member 3, it is possible to prevent the coil member 5 from being deformed or damaged at the time of carrying or mounting work, and also preventing the case member 3 from being damaged during the carrying. it can.

Further, the insulated wire 20 in which the insulating layer 22 is coated on the conductor stranded wire 21 is cut into a predetermined length L ₀ , and one end portion 25 of the insulated wire 20 is fixed to the cylindrical mandrel 30. Is wound around the outer circumference of the mandrel 30 a plurality of times, the one end 25 is opened, and the insulated wire 20 spirally formed by winding is removed from the mandrel 30 to form the coil member 5. decompresses the heart dimension to expand the distance between the insulated wire 20 in a predetermined pitch P _2, by inserting the insulated wire 20 constituting the spiral from one end 25 side to the hole 6A of the ring-shaped core 6, the coil member 5 The ring-shaped core 6 is fitted into the ring-shaped core 6, the coil member 5 is expanded along the circumferential direction of the ring-shaped core 6 to form a fan-like shape, and an integrated coil unit 10 is formed. ,Case The cylindrical fixing member 7 provided on the lid body 3B of the material 3 and the inner surface of the lid body 3B are fixed, the lid body 3B is attached to the box-shaped main body 3A and covered, and one end portion 25 and the other end portion of the insulated wire 20 are applied. Since the coil unit 10 is housed in the case member 3 in a projecting shape, the coil member 5 can be fitted into the ring-shaped core 6 even in a structure using the non-divided closed annular ring-shaped core 6. Assembly work becomes easy and workability can be improved. The noise current suppression characteristics can be stably improved. By storing the coil unit 10 in the case member 3, it is possible to prevent the coil member 5 from being deformed / damaged during transportation and attachment work, and to prevent the case member 3 from being damaged during transportation.

DESCRIPTION OF SYMBOLS 3 Case member 3A Box-type main body 3B Cover body 4 Band plate-shaped holding member 5 Coil member 6 Ring-shaped core 6A Hole part 7 Cylindrical fixing member 8 Band member 10 Coil unit 20 Insulated electric wire 21 Conductor twisted wire 22 Insulating layer 25 One end part 26 other end 30 mandrel L ₀ length P ₂ pitch

Claims (4)

In a noise filter that is inserted into the ground wire of electrical equipment and suppresses the noise current flowing through the ground wire,
A coil member (5) composed of an insulated wire (20) wound spirally, and a plurality of ring-shaped cores (6) (6) fitted in the coil member (5) in a loose-fitting manner The ring-shaped core (6) is formed in a non-divided closed ring, and the spiral insulated wire (20) is formed in the holes (6A) (6A) of the ring-shaped core (6) (6). The insulated wire (20) is helically bound and fixed by the plurality of band members (8) and the coil member (5) and the ring-shaped cores (6) (6) are connected. An integral coil unit (10) is formed,
Further, the coil unit (10) is housed in a case member (3) composed of a box-shaped main body (3A) and a lid (3B), and the box-shaped main body (3A) of the box-shaped main body (3A) is accommodated by a band plate-like pressing member (4). A noise filter characterized by being fixed to the inner surface. In a noise filter that is inserted into the ground wire of electrical equipment and suppresses the noise current flowing through the ground wire,
A coil member (5) composed of an insulated wire (20) wound spirally, and a ring-shaped core (6) fitted in a loose fit in the coil member (5). The core (6) is formed in a non-divided closed ring, the spiral insulated wire (20) is inserted through the hole (6A) of the ring-shaped core (6), and the ring-shaped core (6) The coil member (5) is expanded along the circumferential direction into a fan shape, and an integrated coil unit (10) is formed.
Further, the coil unit (10) is housed in a case member (3) composed of a box-shaped main body (3A) and a lid (3B), and is provided on the lid (3B) by a plurality of band members (8). A noise filter characterized by being fixed to the inner surface of the cylindrical fixing member (7) and the lid (3B). Cut the insulated wire (20) in which the conductor stranded wire (21) is covered with the insulating layer (22) into a predetermined length (L ₀ ),
One end (25) of the insulated wire (20) is fixed to the cylindrical mandrel (30),
The insulated wire (20) is wound around the outer periphery of the mandrel (30) a plurality of times,
Opening the one end (25), removing the insulated wire (20) spirally formed by the winding from the mandrel (30), forming a coil member (5),
Extending the axial direction dimension of the coil member (5), expanding the distance between the insulated wires (20) to a predetermined pitch (P ₂ );
The insulated electric wire (20) having a spiral shape is inserted into the holes (6A) and (6A) of the plurality of ring-shaped cores (6) and (6) from the one end (25) side, and is inserted into the coil member (5). The ring-shaped core (6) (6) is fitted in a loose fit,
The axial dimension of the coil member (5) is shortened, and the spiral insulated wire (20) is bound by a plurality of band members (8), and the coil member (5) and the ring-shaped core ( 6) Connect (6) to form an integral coil unit (10),
The coil unit (10) is fixed to the inner surface of the box-shaped main body (3A) of the case member (3) by the band plate-like pressing member (4), and the one end (25) and the other end of the insulated wire (20). The portion (26) protrudes from the box-type main body (3A), the lid (3B) is attached to the box-type main body (3A), and the case unit (3) is covered with the coil unit (10). A method for manufacturing a noise filter, comprising storing. Cut the insulated wire (20) in which the conductor stranded wire (21) is covered with the insulating layer (22) into a predetermined length (L ₀ ),
One end (25) of the insulated wire (20) is fixed to the cylindrical mandrel (30),
The insulated wire (20) is wound around the outer periphery of the mandrel (30) a plurality of times,
Opening the one end (25), removing the insulated wire (20) spirally formed by the winding from the mandrel (30), forming a coil member (5),
Extending the axial direction dimension of the coil member (5), expanding the interval between the insulated wires (20) to a predetermined pitch (P ₂ ),
The insulated electric wire (20) having a spiral shape is inserted into the hole (6A) of the ring-shaped core (6) from one end (25) side, and the ring-shaped core (6) is idled in the coil member (5). Fit into the fit,
The coil member (5) is expanded along the circumferential direction of the ring-shaped core (6) to form a fan, and an integrated coil unit (10) is formed.
The coil unit (10) is fixed to the inner surface of the cylindrical fixing member (7) and the lid (3B) provided on the lid (3B) of the case member (3) by the band member (8), and the lid The body (3B) is attached to the box-shaped main body (3A) and covered, and one end (25) and the other end (26) of the insulated wire (20) are projected to form the coil unit on the case member (3). (10) is housed, and the manufacturing method of the noise filter characterized by the above-mentioned.

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