JPH0482163B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a winding body forming, for example, a field coil of a starter or a rotor coil of an alternator.

[Conventional technology]

As society's demands for smaller and lighter equipment increase, attempts are being made to increase the density of the coils that make up electromagnetic devices.

On the other hand, in the conventional type, a coil having a circular cross section is used and the coil is wound around a winding frame (bobbin).

[Problem that the invention seeks to solve]

However, in the conventional device described above, when the coil 20 having a circular cross section is wound in layers on the bobbin 21, as shown in FIG. However, since the directions are opposite to each other, a force acts to cause the wire newly wound on the upper layer 20b to follow the lead grooves 20c and 20d of the lower layer 20a in the opposite direction. As a result, the leads 20d of the upper layer 20b become disordered as shown in the figure, and as the layers are stacked, the disorder of the leads 20d increases.

Furthermore, even if the winding machine is highly accurate and the alignment of the coil with a circular cross section is improved to the limit without leader disturbance, the empty space between adjacent round wires cannot be filled.

Therefore, as shown in FIG. 14, instead of using a coil with a circular cross section, a coil 22 with a polygonal cross section is used.
When transitioning from the lower layer to the upper layer by folding back, the coil 22, which has a polygonal cross section, does not fit within the winding frame 23, and the posture of the coil 23 shifts, making it difficult to wind the upper layer.

[Means for solving problems]

Therefore, the present invention provides a winding body comprising a winding frame and a coil that is folded back at the end of the winding frame and wound in multiple layers around the outer periphery of the winding frame, wherein the coil is wound at the folded part. The wire is a round wire with a circular cross section, and is a square wire with a polygonal cross section whose side surfaces are formed by flat parts in other parts, and the adjacent square wires are in contact with each other at the flat parts. The present invention provides a winding body.

[Effect]

By making the folded part a coil with a circular cross section,
When moving from the lower layer to the upper layer, the coil does not lose its posture as in the conventional case, and a coil having a polygonal cross section can be wound.

〔Effect of the invention〕

As described above, in the present invention, by making the folded part a round wire with a circular cross section, the posture of the coil at the folded part is not distorted, and the remaining part is made of a square wire with a polygonal cross section. Since the flat parts of the coils are in contact with each other, there is an excellent effect that the space between adjacent coils can be reduced and the space factor can be improved.

〔Example〕

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention shown in the drawings will be described. FIG. 1 is a partially sectional perspective view showing the overall configuration of an embodiment of a coil winding device for forming a winding body of the present invention.

Reference numeral 1 denotes a reel frame rotation motor, and 2 a reel frame fixing jig, which is directly connected to the reel frame rotation motor 1, and is shown in half cross section in the figure. 3 is a winding frame, which is clamped and fixed between the winding frame fixing jig 2 and the disc 2a. 4a and 4b are wire rods. 5 is a plate, and this plate 5 has forming rollers 6a,
6b, guide nozzles 7a, 7 for wire rods 4a, 4b
b. A forming roller rotation motor 8 is provided. These constitute a wire molding section. Reference numeral 9 denotes a traverse guide motor, which is connected to the plate 5 via a ball screw 11.

The guide nozzles 7a, 7b are fixed to the arm portion 5a of the plate 5, and the rollers 6a, 6b are fixed to the arm portion 5a of the plate 5.
b. It is provided almost in a straight line throughout the gap. Reference numeral 12 designates a mechanical valve, which is pressed and operated by the plate 5 when the plate 5 moves to a position where the layer end folded portion of the coil is wound.
They are disposed on both sides of the plate 5 in the reciprocating direction and function to switch the operating direction of the roller slide cylinder 14.

FIG. 2 is a partial sectional view of the wire molding section in FIG. 1.

Reference numeral 13 denotes a slide block, which is disposed within the slide groove of the plate 5 and is coupled to the roller slide cylinder 14. roller 6b
is rotatably attached to the slide block 13, and the roller 6a is connected to a motor 8 for rotating the forming roller 6.
It is directly connected to the plate 5 and is rotatably held with respect to the plate 5.

Next, to explain the operation of the coil winding device having the above configuration, first, the tip of the round wire rod 4b having a circular cross section is passed through the guide nozzle 7a, between the rollers 6a and 6b, and through the guide nozzle 7b, and is then tied around the outer periphery of the winding frame 3. and fix it.

At this time, the plate 5 is at the position where the layer end folded portion of the coil is wound, that is, at one end of the reciprocating motion (one end of the winding frame 3), and the mechanical bubble 1
Since you are pressing 2, the mechanical bubble 1 at that time
2, the roller slide cylinder 14 is operated, and the slide block 13 holding the roller 6b is moved downward (in the direction of arrow B).
The gap between the rollers 6a and 6b is made larger than the wire diameter of the round wire 4b.

Thereafter, the winding frame rotation motor 1 is operated to wind the wire 4b around the outer periphery of the winding frame 3. At the same time, the traverse guide motor 9 also rotates, and the entire wire molded part (plate 5) shown in FIG. The traverse is performed in synchronization with (the rotation of the winding frame rotation motor 1). When the winding frame 3 rotates once, the plate 5 separates from the mechanical bubble 12, the valve at this time switches, the roller slide cylinder 14 operates, and the slide block 13 is raised.
The roller 6b is moved upward (in the direction of the arrow C) so that the gap between the rollers 6a and 6b obtains a predetermined amount of crushing of the round wire 4b.

Further, the forming roller 6a is rotated by the operation of the forming roller rotation motor 8, and continuously draws the round wire 4b between it and the roller 6b.
Crush b and make a flat wire 4 as shown in Figure 3.
Mold a. During this time, the round wire 4b is stably guided through the guide nozzle 7a to a predetermined position between the pair of forming rollers 6a, 6b. After that, it is formed into a rectangular shape and passes through the guide nozzle 7b to the winding frame 3.
be led to.

In this way, when the plate 5 moves to the other end (the other end of the winding frame 3) while winding the flat wire 4a,
Push the mechanical bubble 12 again and the bubble will switch from the rectangular wire 4a back to the round wire 4b. This operation is repeated until the end of the winding, that is, the folded end portion of the layer is wound with round wire, the other portions are wound with rectangular wire, and this process is repeated continuously.

In addition, when making the round wire 4b into the flat wire 4a, the impression ratio = l/t, where the width of the flat wire 4a is l and the other thicknesses are t, should be approximately 1.5 or less based on experiments. The insulation coating on the outer periphery of the wire 4b is not destroyed.

Therefore, with the above-mentioned configuration, the wire 4 is first wound as a round wire 4b until it is wound around the winding frame 3, and then as a flat wire 4a when it is wound around the winding frame 3. It is easy to keep the cross-sectional posture constant, and since the wire rod 4 is a round wire rod 4b, it is easy to unwind the wire rod 4 from the drum (on which the wire rod 4 is wound) without twisting.

Also, when first tying the tip of the wire 4 to the winding frame 4, use the round wire 4b, and after tying the tip,
In order to form the flat wire 4a and wind it around the winding frame 3,
The wire rod 4 can be wound very easily without twisting the wire.

In addition, since the layer end folded portion is wound with the round wire 4b, as shown in Fig. 12, at the layer end folded portion,
When the winding moves from the lower layer to the upper layer, the rectangular wire 4a
This eliminates the problem of poor posture.

Furthermore, since the rectangular wire 4a is wound around the winding frame 3, the number of lead grooves between the rectangular wires 4a is reduced.
This allows winding with a high degree of alignment to be achieved.

In the second embodiment shown in FIG. 4, a first roller 6a is fixed to the tip of a shaft 8a of a motor 8 for rotating the forming roller. Note that the shaft 8a
A first bevel gear 15 is fixed on the top, and a second bevel gear 16 meshes with the first bevel gear 15. A second roller 6b is fixed to the shaft 17 to which the bevel gear 16 is fixed. Then, the first and second rollers 6a, 6b
are arranged at right angles.

Further, 14a is a first roller slide cylinder, 13a is a first slide block, 6c is a third roller rotatably provided on the first slide block 13a, and this third roller 6c
is arranged in a straight line with the first roller 6a, and is indicated by the arrow D.
direction, the first roller slide cylinder 14a
Move accordingly.

Further, 14b is a second roller slide cylinder, 13b is a second slide block, and 6d is a fourth roller rotatably provided on the second slide block 13b.
is arranged in a straight line with the second roller 6d, and extends in the direction of the arrow E to the second roller slide cylinder 14.
Move by b.

Then, as shown in Fig. 4, the first to fourth
A square gap 18 is formed by the rollers 6a to 6b.
form.

Then, as in the first embodiment described above, by inserting the round wire 4b into the gap 18, the round wire 4b can be made into a square-shaped square wire 4c. Also, when wrapping the round wire rod 4b around the winding frame,
first and second roller slide cylinders 14a,
14b, the third and fourth rollers 6c and 6d are moved, and the first to fourth rollers 6a to 6b are moved.
The gap formed by this is assumed to be larger than the diameter of the round wire 4b. After the tip of the round wire 4d is wrapped around the winding frame, the round wire 4b is turned into a square wire 4c, and the square wire 4c is wound around the winding frame 3 as shown in FIG.

Furthermore, when the degree of alignment is improved to the limit for both round wire and flat wire, the square wire-wound coil shown in Figure 5 will have smaller gaps between the wires than the round wire-wound coil shown in Figure 6. There is an effect. Comparing this in terms of space factor, assuming that the cross-sectional shape of the rectangular wire is rectangular, the rectangular wire-wound coil is
The advantage is that the space factor is 27.4% higher than that of a round wire wound coil. The formula below is the calculation formula.

Here, the space factor=Σ(wire cross-sectional area)/(windable space cross-sectional area).

Then, the space factor of the diagonally shaded area (the square area of 3a vertically and 3a horizontally) shown in FIGS. 7 and 8 is calculated. Here, a is the wire diameter of the round wire 4b.

Space factor of conventional coil: {9×(π/4)a ² /(3a) ² } ×100=78.5% Space factor of coil according to the present invention: (total cross-sectional area of wire)/(3a) ² × 100=100% {(100%-78.5%)/78.5%} ×100=27.4% (In the coil according to the present invention, there is no empty space between adjacent wires, so theoretically the space factor is 100.
It is expressed as a percentage. ) Since the coil manufactured by the coil winding device of the present invention has a rectangular wire material, the upper layer of the coil is not affected by the lower layer leads, improving the degree of alignment. It becomes easy to wind a coil without a winding frame as shown in FIG. 9, a trapezoidal coil as shown in FIG. 10, and the like.

Although the first to fourth rollers 6a to 6b are used to form the round wire 4b into the rectangular wire 4a as shown in FIG. good.

In FIG. 11, opposing protrusions 6e' and 6f' are formed at one end of a pair of rollers 6e and 6f, respectively, and a square gap is formed between the pair of rollers 6e and 6f.

In the one in Figure 12, a pair of rollers 6g, 6h
and a pair of rollers 6 respectively.
Triangular grooves 6g' and 6h' are formed on the outer peripheries of grooves 6g and 6h, and a square gap is formed between the grooves 6g' and 6h'.

[Brief explanation of the drawing]

FIG. 1 is a partial cross-sectional perspective view showing the overall configuration of a first embodiment of a coil winding device for forming a winding body of the present invention, FIG. 2 is a partial cross-sectional view of the wire forming part shown in FIG. 1, and FIG. The figure is a perspective view showing the roller and the wire, and FIG.
FIGS. 5 to 8 are schematic diagrams showing the present invention in comparison with conventional coils. FIGS. 9 and 10 are schematic diagrams showing other embodiments of the coil according to the present invention. The schematic diagram, FIG. 11 and FIG. 12 are a front view and FIG. 13 showing other embodiments of the roller, respectively.
The figure is a perspective view showing a conventional round wire rod in which the upper layer leads follow the lead grooves in the lower layer, causing the upper layer leads to become disordered. Figure 14 shows a state in which the orientation of the rectangular wire is deviated at the folded end of the layer. FIG. DESCRIPTION OF SYMBOLS 1...Reeling frame rotation motor, 2...Reeling frame fixing jig, 3...Reeling frame, 4a...Flat wire, 4b...Round wire, 5...Plate, 6a, 6b...Forming roller, 7a , 7b... Nozzle, 8... Molding roller rotation motor, 9... Traverse guide motor,
11... Ball screw, 12... Mechanical bubble, 13... Slide block, 14... Cylinder for roller slide.

Claims (1)

[Claims] 1. A winding body consisting of a winding frame and a coil that is folded back at the end of the winding frame and wound in multiple layers around the outer periphery of the winding frame, wherein the first coil is wound at the folded part. It is a round wire with a circular cross section, and is a square wire with a polygonal cross section whose side faces are formed by flat parts in other parts, and the adjacent square wires are in contact with each other at the flat parts. Winding body.