JP7615396B2 - Winding forming device, coil, and coil manufacturing method - Google Patents

Description

This application relates to a winding forming apparatus, a coil using this winding forming apparatus, and a method for manufacturing the coil.

Superconducting coils for accelerators and the like require the use of non-circular irregular coils. For example, Patent Document 1 discloses a method for manufacturing such non-circular irregular coils, which involves manufacturing an irregular coil with a concave negative curvature on the inside of the coil. Patent Document 2 discloses a winding device that winds wire into a shape that connects multiple radii of curvature.

JP 2015-159162 A (FIG. 1) JP 2000-148517 A (FIG. 5)

However, in Patent Document 1, the portion having negative curvature is manufactured by winding the conductor while adhering it to the reel with an adhesive, and then dissolving the adhesive as a post-processing step. This requires complex steps of adhering and dissolving during the manufacturing process, and creates problems such as the expense of the adhesive and the time required for the manufacturing process.

In addition, the winding device of Patent Document 2 is capable of forming a non-circular winding shape with multiple curvatures by changing the relative positions between three pairs of rolls. Although this is effective for forming a winding with different positive curvatures that bulge outward from the coil, there is a problem with forming a winding of a coil with positive and negative curvatures that have repeated concaves and convexes.
When bending the conductor to form the negative curvature recessed inside the coil using the same winding forming device, the adjustment range between the rolls of the forming device must be expanded, which increases the size of the forming device and the cost of the device. In addition, the conductor after forming is subject to large swings due to the change in the positive and negative curvatures, which necessitates a large range of motion for the winding device.

This application has been made to solve the above problems. The purpose is to obtain a winding forming device that can form a winding in which the conductor has continuous positive and negative curvatures, and that can also reduce the size of the device itself.

The winding forming device of the present application is a winding forming device that forms a conductor into a coil shape, and is equipped with a first winding forming roller that forms the conductor into a positive curvature, and a second winding forming roller that forms the conductor into a negative curvature, and at least one of the first winding forming roller and the second winding forming roller is detachably mounted on the conductor being formed.

According to the present application, a first winding forming roller that forms the conductor into a positive curvature and a second winding forming roller that forms the conductor into a negative curvature are provided, one of which is detachable from the conductor, so that a winding in which the conductor has continuous positive and negative curvatures can be formed with a simple configuration.

1 is a schematic diagram showing a configuration of a winding forming device according to a first embodiment; 2 is a cross-sectional view taken along line AA of FIG. 1 , showing a first winding forming roller according to the first embodiment. 2 is a cross-sectional view taken along line BB of FIG. 1 , showing a second winding forming roller according to the first embodiment. 4 is a side view showing a first winding forming roller, a second winding forming roller, and a winding forming roller attachment/detachment mechanism according to the first embodiment; FIG. 2 is a perspective view showing the shape of a conductor formed by the winding forming device according to the first embodiment; FIG. 1 is a perspective view showing a method of shaping a conductor using a winding shaping device according to a first embodiment; 3 is a schematic diagram showing a lamination process of a conductor formed by the winding forming device according to the first embodiment; FIG. 11A and 11B are schematic diagrams showing a plan view and a side view of a winding forming device according to a second embodiment. FIG. 11 is a schematic diagram showing the configuration of a winding forming device according to a third embodiment. 9 is a cross-sectional view taken along the line CC of FIG. 8 , showing a first winding forming roller according to a third embodiment. 13A and 13B are schematic diagrams showing a plan view and a side view of a winding forming device according to a fourth embodiment.

Embodiment 1.
Hereinafter, a first embodiment of the present application will be described with reference to FIG. 1. FIG. 1 is a schematic diagram showing the configuration of a winding forming device 100 according to the first embodiment. In FIG. 1, a conductor 1 is fed to a first winding forming roller 3 by a feeding mechanism 2. The first winding forming roller 3 is a bending roller for forming the conductor into a positive curvature that is the base of the coil winding, and is placed on the same plane as the feeding mechanism 2. The conductor 1 formed by the first winding forming roller 3 is guided vertically downward along a guide 4 and fed to the position of a second winding forming roller 5 for forming the conductor into a negative curvature. The second winding forming roller 5 is provided so as to be detachable from the conductor 1 to be formed by a detaching mechanism 6 described later. Furthermore, the second winding forming rollers 5 are provided in a plurality of stages in the vertical direction, and the guide 4 is arranged so as to guide the formed conductor 1 between these second winding forming rollers 5.

Here, for the irregularly shaped coil manufactured as the final product, the curvature of the conductor in the portion that bulges outward of the coil is defined as positive curvature, and the curvature of the conductor that is recessed inward of the coil is defined as negative curvature. In FIG. 1, the conductor 1 fed by the feed mechanism 2 is initially shaped to a positive curvature by the first winding shaping roller 3, but it is also possible to use the second winding shaping roller 5 to shape this portion to a negative curvature. In that case, the positions of the first winding shaping roller 3 and the second winding shaping roller 5 are interchanged, and the combination with the attachment/detachment mechanism 6 is also reversed. In the following, an example of the arrangement in FIG. 1 will be described in which the first shaping of the conductor 1 is performed by the first winding shaping roller 3 to shape it to a positive curvature.

2A is a cross section taken along line AA in FIG. 1, showing the relationship between the first winding forming roller 3 and the conductor 1. FIG. 2B is a cross section taken along line BB in FIG. 1, showing the relationship between the second winding forming roller 5 and the conductor 1. FIG. 3 is a schematic diagram showing the first winding forming roller 3 and the second winding forming roller, and the attachment/detachment mechanism 6 for these rollers. In FIG. 3, 71 denotes a roller, and three rollers 71 are arranged to sandwich the conductor 1 and are provided on a roller stand 72. Depending on the arrangement of these rollers 71, the conductor 1 is used as the first winding forming roller 3, which forms the conductor 1 into a positive curvature, and the second winding forming roller 5, which forms the conductor 1 into a negative curvature. Although the conductor 1 is formed using three rollers 71, the number of rollers is not limited to three, and may be four or more, or may be opposing rollers. The rollers 71 do not have to be the same size.

The detachment mechanism 6 has a lift structure that moves the roller base 72 up and down together with the roller 71. Although not shown, the detachment mechanism 6 may have a mechanism that opens and closes the gap between the conductor 1 and the roller 71 by linking it with the roller base 72 or the roller 71 so that the conductor 1 can be attached and detached smoothly. Although the detachment mechanism 6 is shown as an example of a lift structure provided on the floor, the detachment mechanism 6 may be provided without a floor or lift structure, with the roller base 72 itself being able to change the clamping gap of the roller 71 to apply and release pressure to the conductor 1. Alternatively, any other method may be used as long as it has a structure that allows the roller 71 to be detached from the conductor 1.

Next, the winding forming operation by the winding forming device 100 described above will be described. In FIG. 1, the conductor 1 is sent to the first winding forming roller 3 by the feed mechanism 2 and is formed with a positive curvature. After passing through the first winding forming roller 3, the conductor 1 advances vertically downward along the guide 4. At this time, the position of the formed conductor 1 is not restricted. When the conductor 1 advances to a predetermined position, the second winding forming roller 5 is set by the attachment/detachment mechanism 6 to a position guided by the guide 4, and the conductor 1 is formed with a negative curvature only for the length required for the design shape. When the required length has been formed, the second winding forming roller 5 is removed from the conductor 1 by the attachment/detachment mechanism 6. The conductor 1 formed with a negative curvature advances vertically downward again along the guide 4. The conductor 1 is shaped into a winding shape with continuous positive and negative curvatures by adjusting the curvature with the first winding forming roller 3 and repeating the setting, forming, releasing and detachment of the multiple second winding forming rollers 5 in accordance with the winding shape with continuous positive and negative curvatures.

Figure 4 shows an example of a conductor 1 being formed by the winding forming device 100, where the conductor 1 has alternating positive curvature portions 1a and negative curvature portions 1b. Here, the positive curvature portions 1a are formed by the first winding forming roller 3 shown in Figure 1. The negative curvature portions 1b are formed by the second winding forming roller 5 in the subsequent stage. Next, the forming of the negative curvature portion 1b by attaching and detaching the second winding forming roller 5 is shown in Figure 5. The attaching and detaching movement of the second winding forming roller 5 is indicated by the arrows in the figure. As shown on the left side of Figure 5, a shaping is applied to the conductor 1 to give it a negative curvature for the required length using the attachment/detachment mechanism 6 so as to form the negative curvature portion 1b. 5, the front second winding forming roller 5 is removed from the conductor 1 by the attachment/detachment mechanism 6, and the rear second winding forming roller 5 arranged vertically is set by the attachment/detachment mechanism 6, and the conductor 1 is shaped to have a negative curvature over the required length. Although the two front and rear second winding forming rollers 5 have been described as being the same, rollers with different curvatures may also be used. In this way, it is possible to form the conductor 1 with partially different curvatures.

In this way, the formed conductor 1 is guided vertically as shown in Figure 6, and is stacked on the winding table 8 as the laminated section 1c. As shown in the enlarged view of the laminated section 1c, the conductor 1 is stacked in a coil shape. At this time, the winding table 8 may be made movable, for example, back and forth, left and right, up and down, and rotated, to match the formed shape of the conductor 1. By using the conductor 1 stacked in the laminated section 1c as a winding, it is possible to manufacture irregularly shaped coils with positive and negative curvatures.

As described above, the winding forming device 100 of embodiment 1 comprises a first winding forming roller 3 that forms the conductor 1 into a positive curvature, and a second winding forming roller 5 that forms the conductor 1 into a negative curvature, and the second winding forming roller 5 is arranged to be detachable from the conductor 1 being formed.

This makes it possible to form a winding in which the conductor has continuous positive and negative curvature with a simple configuration. Also, because the second winding forming roller 5 is arranged vertically, space for attachment and detachment can be easily secured, making it possible to reduce equipment costs. Also, because the first winding forming roller 3 and the second winding forming roller 5 differ only in that the roller arrangement with respect to the conductor 1 is reversed, it is possible to standardize many parts and reduce equipment costs.
It is also possible to change the relative position of the roller 71 between the first winding forming roller and the second winding forming roller in accordance with the forming location of the conductor 1, thereby changing the curvature of the conductor 1. In this way, winding forming with complex changes in curvature is possible.
In addition, the conductor 1 formed by this winding forming apparatus can be used as a winding to manufacture coils of irregular shapes.

Although an example has been shown in which the conductor 1 after shaping is guided in the vertical direction, if the final product, the coil, is roughly cylindrical, the same processing can be achieved by guiding the wire in a shifted manner in the winding direction, with the direction in which the wire is wound being the cylindrical direction of the cylinder as the winding direction. In that case, the first winding forming roller and the second winding forming roller are positioned shifted in the winding direction. Also, in that case, a winding device that matches the coil shape after shaping at the final lamination stage of the conductor 1 may be provided. By arranging the wires in this way without being concerned about the vertical direction, the vertical installation space can be reduced.

Embodiment 2.
7 is a schematic diagram for explaining the configuration of a wire winding forming apparatus 100 according to embodiment 2, with a plan view shown at the top and a side view shown at the bottom. The same parts as those in embodiment 1 shown in FIG. 1 are indicated by the same reference numerals, and detailed explanations will be omitted. In embodiment 1, the second wire winding forming rollers 5 are disposed offset in the vertical direction, but they can also be disposed horizontally on the same plane.

As shown in Fig. 7, the conductor 1 is formed into a positive curvature by the first winding forming roller 3, and then guided to the second winding forming roller 5 in the preceding stage, and the formed conductor 1 is further guided to the second winding forming roller 5 in the succeeding stage. However, as shown in Fig. 7, the movements of the conductor 1 are guided on the same plane, and the conductor 1 formed by the second winding forming roller 5 in the succeeding stage is guided in the vertical direction by a guide 4 as indicated by the dashed line.
In embodiment 1, space was required in the vertical direction to position the second winding forming roller, but in embodiment 2, a guide 4 is required to avoid interference when the formed conductor makes one full turn and returns to the bending start position, but it is possible to reduce the vertical space compared to embodiment 1.

Although an example has been shown in which the conductor 1 after shaping is guided in the vertical direction, similar to embodiment 1, the conductor 1 shaped by the second winding shaping roller 5 in the subsequent stage can also be guided in the winding direction by the guide 4 to perform the same processing. In that case, the first winding shaping roller 3 and the second winding shaping roller 5 can be arranged on the same plane without being limited to a horizontal plane. By arranging them in this way without being limited to a vertical direction, the vertical installation space can be reduced.

Embodiment 3.
Fig. 8 is a schematic diagram showing the configuration of a wire winding forming apparatus 100 according to embodiment 3. The same parts as those in Fig. 1 shown in embodiment 1 are designated by the same reference numerals, and detailed explanations will be omitted. A cross section taken along the line CC in Fig. 8 is shown in Fig. 9. Cross sections AA and BB are the same as those in Figs. 2A and 2B.

In the first embodiment, the positive curvature is adjusted by the first winding forming roller 3 installed first. However, as shown in FIG. 8, by arranging multiple downstream first winding forming rollers 3 that add detachable positive curvature on the guide 4 of the conductor 1, it is possible to correct and adjust the bending shape that cannot be controlled by only one first winding forming roller 3. For example, this is the case when the positive curvature caused by the bending of the first winding forming roller is initially affected by the forming by the second winding forming roller 5. This correction and adjustment makes it possible to create a winding forming device that can handle complex shapes with higher precision.

Embodiment 4.
10 is a schematic diagram showing the configuration of a wire winding forming apparatus 100 according to embodiment 4, with a plan view shown at the top and a side view shown at the bottom. The same parts as those shown in FIG. 1 for embodiment 1, FIG. 7 for embodiment 2, and FIG. 8 for embodiment 3 are designated by the same reference numerals, and detailed explanations will be omitted.

In the above embodiment 3, the first winding forming roller 3 that adds positive curvature in the subsequent stage is disposed offset in the vertical direction. However, as shown in FIG. 10, it is also possible to dispose a plurality of subsequent first winding forming rollers 3 in the same horizontal plane.
In this case, as in embodiment 2, a guide 4 is required to avoid interference when the formed conductor makes one revolution and returns to the bending start position, but it is possible to reduce the vertical space compared to embodiment 3. Also, as in embodiment 3, it is possible to make corrections and adjustments when the positive curvature caused by the initial bending of the first winding forming roller is affected.

Although an example has been shown in which the conductor 1 after shaping is guided in the vertical direction, similar processing can be performed by guiding the shaped conductor 1 in the winding direction using the guide 4, as in embodiment 2. In that case, the first winding shaping roller 3 and the second winding shaping roller 5 can be provided on the same plane without being limited to a horizontal plane. By arranging them in this way without being limited to a vertical direction, the vertical installation space can be reduced.

Although various exemplary embodiments and examples are described in this application, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but can be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are expected within the scope of the technology disclosed in this specification. For example, this includes cases in which at least one component is modified, added, or omitted, and even cases in which at least one component is extracted and combined with components of other embodiments.

1 Conductor, 1a Positive curvature portion, 1b Negative curvature portion, 1c Stacking portion, 2 Feed mechanism, 3 First winding forming roller, 4 Guide, 5 Second winding forming roller, 6 Detachment mechanism, 71 Roller, 72 Roller stand, 8 Winding stand, 100 Winding forming device.

Claims (8)

A winding forming device for forming a conductor into a coil shape, comprising:
a first winding forming roller for forming the conductor into a positive curvature;
a second winding forming roller for forming the conductor into a negative curvature;
Equipped with
a winding forming apparatus, characterized in that at least one of the first winding forming roller and the second winding forming roller is provided so as to be detachable from the conductor to be formed. The winding forming device according to claim 1, characterized in that the first winding forming roller and the second winding forming roller are arranged offset in the winding direction. The winding forming device according to claim 1, characterized in that the first winding forming roller and the second winding forming roller are arranged offset in the vertical direction. The winding forming device according to claim 1, characterized in that the first winding forming roller and the second winding forming roller are arranged in the same plane, and a guide is provided to guide the conductor formed by the first winding forming roller and the second winding forming roller in the winding direction. The winding forming device according to claim 1, characterized in that the first winding forming roller and the second winding forming roller are arranged in the same horizontal plane, and a guide is provided to guide the conductor formed by the first winding forming roller and the second winding forming roller in the vertical direction. A winding forming device as described in any one of claims 1 to 5, characterized in that a plurality of either the first winding forming roller or the second winding forming roller are provided, and at least one of the rollers is detachably provided. A coil manufactured by the winding forming device described in any one of claims 1 to 6. A method for manufacturing a coil, comprising the step of forming a coil conductor using a winding forming device as described in any one of claims 1 to 6.

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