JP2010027718A - Air-core coil, and winding method and winding device therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an air-core coil in which winding end lead portion is shaped to be along a side surface winding portion of a coil portion, and to provide a winding method and a winding device therefor. <P>SOLUTION: The air-core coil 1 has the winding end lead portion 5 extending from an outer peripheral winding portion 3c of the coil portion 3, and the winding end lead portion 5 has a winding end lead base end curved portion 5a extending while curved along the side surface winding portion 3b of the coil portion 3 between the outer peripheral winding portion 3c and an inner peripheral winding portion 3a. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an air-core coil, a winding method thereof, and a winding device.

  In general, an air-core coil has a coil portion in which a wire is wound in a spiral shape, a winding start lead portion made of a wire extending from the inner periphery of the coil portion, and a winding end lead portion made of a wire extending from the outer periphery of the coil portion (See Patent Document 1).

In the conventional winding device for forming this type of air-core coil, after winding the wire fed from the nozzle around a rotating winding core, the excess wire is cut by a cutter, and the winding start lead portion and winding end lead portion The winding work was completed in a state where the wire was extended in the winding direction.
Japanese Patent Laid-Open No. 10-303015

  However, in the conventional winding device, the winding operation is completed with the winding start lead portion and the winding end lead portion extending in the winding direction. Therefore, as a process before connecting the air-core coil to the substrate, Due to the work, it is necessary to shape the winding start lead portion and the winding end lead portion so as to extend in a predetermined direction from the coil portion, and there is a problem that this shaping work takes time.

  The present invention has been made in view of the above problems, and provides an air-core coil, a winding method and a winding device for shaping an air-core coil winding end lead portion so as to follow a side surface winding portion of the coil portion. The purpose is to provide.

  The present invention provides a coil portion in which a wire is wound in a spiral shape, a winding start lead portion made of a wire extending from the inner peripheral winding portion of the coil portion, and a winding end lead made of a wire extending from the outer peripheral winding portion of the coil portion The winding end lead portion has a winding end lead proximal curved portion extending curvedly along the side winding portion of the coil portion between the outer winding portion and the inner winding portion. It is characterized by having.

  The present invention also provides a coil portion in which a wire is wound in a spiral shape, a winding start lead portion made of a wire extending from the inner peripheral winding portion of the coil portion, and a winding made of a wire extending from the outer peripheral winding portion of the coil portion. A coil winding method for forming an air core coil having an end lead portion, wherein a winding step of winding a wire fed from a nozzle around a winding core to form a coil portion, and shaping a wire extending from an outer peripheral winding portion From the coil part, a shaping process of the winding end lead part that forms a winding end lead base end curved part that curves and extends along the side surface winding part of the coil part between the outer peripheral winding part and the inner peripheral winding part, And an extraction step of extracting the core.

  The present invention also provides a coil portion in which a wire is wound in a spiral shape, a winding start lead portion made of a wire extending from the inner peripheral winding portion of the coil portion, and a winding made of a wire extending from the outer peripheral winding portion of the coil portion. A coil winding apparatus for forming an air-core coil having an end lead portion, a nozzle for feeding out a wire, a core around which a wire fed from the nozzle is wound, and a forming that moves relative to the core A winding step in which a wire rod fed from a nozzle is wound around a winding core to form a coil portion, and an outer circumferential winding portion and an inner circumferential winding are shaped by winding a wire rod extending from the outer circumferential winding portion around a forming device. A winding end lead portion forming a winding end lead base end bending portion that curves and extends along the side surface winding portion of the coil portion, and the winding core is extracted from the coil portion Characterized by being configured to perform the come-up process.

  According to the present invention, it becomes possible to automatically form an air-core coil shaped so that the winding end lead portion is along the side surface winding portion of the coil portion, eliminating the need to manually shape the end lead portion, Increase productivity.

  Even if the winding end lead portion is pulled in the outer diameter direction of the coil portion, the winding end lead proximal curved portion bent along the side winding portion of the winding end lead portion is bent and deformed, so that the outer peripheral winding portion of the coil portion is deformed. Is prevented from breaking, and an excessive stress is applied to the wire to prevent disconnection, and the shape of the coil portion is maintained.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

  1A is a side view of the air-core coil 1, FIG. 1B is a sectional view taken along the line AA in FIG. 1A, and FIG. 1C is taken along the line BB in FIG. It is sectional drawing. The air-core coil 1 is used as a component that drives an arm of a hard disk device, for example.

  The air-core coil 1 includes a coil part 3 in which a wire 2 is wound in a trapezoidal spiral shape, a winding start lead part 4 composed of a wire 2 extending from the inner periphery of the coil part 3, and a wire extending from the outer periphery of the coil part 3 2 and a winding end lead portion 5 made of two.

  The winding start lead portion 4 and the winding end lead portion 5 are shaped so as to extend from the winding center axis O of the coil portion 3 side by side in the radial direction. The winding start lead portion 4 and the winding end lead portion 5 extend substantially in parallel with a predetermined interval.

  The coil portion 3 in which the wire 2 is wound in a multilayered spiral shape has an inner peripheral winding portion 3a made of the wire rod 2 arranged on the inner periphery thereof, an outer peripheral winding portion 3c made of the wire rod 2 arranged on the outer periphery thereof, and both sides thereof. A pair of side surface winding portions 3b made of the wire rods 2 arranged side by side.

  The winding start lead portion 4 has a winding start lead base end portion 4 a that extends from the inner circumferential winding portion 3 a of the coil portion 3 while being bent and extends along the side surface winding portion 3 b of the coil portion 3.

  The winding end lead portion 5 has a winding end lead proximal end curved portion 5a extending from the outer peripheral winding portion 3c of the coil portion 3 while being bent and extending along the side surface winding portion 3b of the coil portion 3.

  The surface of the wire 2 is coated with a fusion layer, and the fusion layer is heated and melted when the coil portion 3 is wound to solidify after being melted, whereby the shape of the coil portion 3 is maintained.

  The winding start lead base end portion 4a and the winding end lead base end bending portion 5a are fixed (welded) to the side surface winding portion 3b of the coil portion 3 through a fusion layer coated on the surface of the wire 2. Each shape is maintained.

  However, the present invention is not limited to this, and the winding start lead base end portion 4 a and the winding end lead base end bending portion 5 a may be configured not to be fixed to the side surface winding portion 3 b of the coil portion 3.

  The surface of the wire 2 is coated with an insulating layer, but the insulating layer is peeled off from the leading end of the winding start lead portion 4 and the leading end of the winding end lead portion 5, for example, a process of assembling to a hard disk device. In this way, it is connected to a board provided in the hard disk device by soldering or the like.

  FIG. 2 is a perspective view showing a schematic configuration of the coil winding device 10 forming the air-core coil 1. Here, three axes X, Y, and Z orthogonal to each other are set, the X axis extends in a substantially horizontal lateral direction, the Y axis extends in a substantially horizontal front-rear direction, and the Z axis extends in a substantially vertical direction. The structure of will be described.

  First and second spindles 20 and 30 that rotate on the same X axis are provided on the gantry 11, and first and second winding jigs 40 and 35 are attached to the first and second spindles 20 and 30, As will be described later, the coil portion 3 is formed by winding the wire 2 via the first and second winding jigs 40 and 35.

  The first spindle 20 is rotatably supported by the first head 21 and is rotationally driven by a first spindle motor 22 via a belt 23 and a pulley.

  The first head 21 is supported on the gantry 11 via a linear guide 24 so as to be movable in the X-axis direction, and is driven by the moving device 25 so as to move in the X-axis direction.

  The moving machine 25 includes a ball screw 28 that is rotationally driven by a servo motor 27, a follower 29 that is screwed into the ball screw 28 and moves in parallel.

  The second spindle 30 is rotatably supported by the second head 31 and is rotationally driven by a second spindle motor 32 via a belt 33 and a pulley. The second head 31 is fixed on the gantry 11.

  As shown in FIG. 3, the winding core 42 protrudes from the jig end surface 41 of the first winding jig 40, while the concave portion 37 that opens to the jig end surface 36 is formed in the second winding jig 35. When the first spindle 20 is moved in the X-axis direction by the moving device 25 and approaches the second spindle 30, the tip end portion 42 a of the core 42 is fitted into the recess 37.

  The cross section of the winding core 42 and the concave portion 37 is formed in a substantially trapezoidal shape and is along the inner peripheral cross-sectional shape of the coil portion 3. It is good also as a shape.

  The winding core 42 is supported so as to be movable in the X-axis direction with respect to the first winding jig 40, and is configured to protrude from the jig end surface 41 so as to protrude and retract. A rod 43 is connected to the winding core 42, and the first winding jig 40 and the first spindle 20 have a hollow structure through which the winding core 42 and the rod 43 penetrate, and protrude from the first spindle 20 of the rod 43. The end is connected to the follower 49 of the mobile unit 45 via a bearing 46. The moving device 45 includes a ball screw 48 that is rotationally driven by a servo motor 47 and a follower 49 that is screwed into the ball screw 48 to move in parallel. The rod 43 is moved in the X-axis direction via the follower 49. To do. The winding core 42 is switched between a winding position that protrudes from the jig end surface 41 and a retracted position that is retracted so as not to protrude from the jig end surface 41 by the operation of the moving device 45.

  On the gantry 11, a nozzle base 50 is provided that moves in the three-axis directions of X, Y, and Z by moving machines 51, 52, and 53. The mobile device 51 moves the X-axis direction moving table 56 in the X-axis direction with respect to the gantry 11. The mobile device 52 moves the Y-axis direction moving table 57 in the Y-axis direction with respect to the X-axis direction moving table 56. The moving machine 53 moves the nozzle table 50 in the Z-axis direction with respect to the Y-axis direction moving table 57. The mobile units 51, 52, and 53 are configured by a ball screw that is rotationally driven by a servo motor and a follower that is screwed into the ball screw to move in parallel.

  A nozzle 58 is fixed to the nozzle base 50, and the wire 2 is supplied to the nozzle 58 from a wire supply source (not shown).

  The nozzle base 50 is provided with a coating peeling machine 59. The coating peeling machine 59 covers the fusion layer and the insulating layer within a predetermined range from the wire 2 by a cutter that rotates around the wire 2 based on a command from the controller. This is to be peeled off, and this has been filed by the present applicant as Japanese Patent Application No. 2000-216443.

  The nozzle base 50 is provided with a wire rod presser 55. The wire rod presser 55 clamps the wire 2 via a presser member that moves by a cylinder based on a command from the controller, and the wire 2 does not come out of the nozzle 58. Like that.

  The nozzle base 50 is provided with a cutter 61 movably in the Z-axis direction via a cylinder 62. The cutter 61 cuts the wire 2 based on a command from the controller.

  A wire guide 63 is provided on the nozzle base 50 via a cylinder 64 so as to be movable in the Z-axis direction. As shown in FIG. 9 (10), the wire rod guide 63 guides the wire rod 2 between two guide rods 65 extending in the Z-axis direction. The distance between the two guide rods 65 is set to be larger than the outer diameter of the wire rod 2 by a predetermined clearance so that the wire rod 2 fed out from the nozzle 58 passes between the guide rods 65 smoothly. Thereby, since the interval between the two guide bars 65 is set smaller than the opening diameter of the nozzle 58, the wire 2 can be guided with high accuracy by guiding the wire 2 through the two guide bars 65. In addition, the speed at which the wire 2 is wound can be increased.

  The wire rod guide 63 is switched between a winding position where the wire rod 2 is guided between the guide rods 65 through the wire rod 2 and a retracted position where each guide rod 65 is separated downward from the wire rod 2 by operation of the cylinder 64.

  On the gantry 11, a forming table 80 is provided that moves in the three-axis directions of X, Y, and Z by the mobile devices 71, 72, and 73. The mobile device 71 moves the X-axis direction moving table 76 in the X-axis direction with respect to the gantry 11. The moving device 72 moves the Y-axis direction moving table 77 in the Y-axis direction with respect to the X-axis direction moving table 76. The moving machine 73 moves the forming table 80 in the Z-axis direction with respect to the Y-axis direction moving table 77. The mobile units 71, 72, and 73 are configured by a ball screw that is rotationally driven by a servo motor, a follower that is screwed into the ball screw and moved in parallel.

  A forming device 81, a clamp 84, a cutter 83, and an ejector 85 are attached to the forming table 80, and work such as cutting and shaping of the winding start lead portion 4 and the winding end lead portion 5 is performed as will be described later. ing.

  As shown in (21) of FIG. 12 described later, the forming device 81 includes a forming plate 88 formed in a flat plate shape extending in the X-axis and Z-axis directions, and winding of the coil unit 3 from the tip of the forming plate 88. And a rod-shaped forming pin 82 protruding in the direction of the rotation center axis O (X axis).

  In the coil winding device 10, after forming the coil portion 3, the forming pin 82 that protrudes from the forming plate 88 by moving the nozzle 58 in a state where the forming plate 88 is in contact with the side surface winding portion 3 b of the coil portion 3. A winding end lead proximal curved portion 5a that curves and extends along the side surface winding portion 3b of the coil portion 3 is formed by winding the wire 2 that becomes the winding end lead portion 5 around the winding end lead portion 5.

  A hot air blower 90 is provided on the gantry 11, and the hot air blower 90 blows out hot air based on a command from the controller, and heats the fusion layer coated on the wire 2 when the coil portion 3 is wound. It is designed to melt.

  As shown in FIG. 3, the second winding jig 35 has a concave portion 37 opened in the jig end surface 36, and the first spindle 20 moves in the X-axis direction. The tip end portion 42 a of the core 42 is fitted into the recess 37.

  As a wire end holding means for holding the tip end portion of the wire 2, a binding rod 38 is provided on the second winding jig 35. A slit 39 is formed at the tip of the binding rod 38. As shown in FIGS. 5 (a) and 5 (b), the wire 2 is passed through the slit 39 and thereby the second winding jig 35 is wound. In contrast, the tip of the wire 2 is held.

  The second winding jig 35 is formed with a lead guide groove 12 in which the wire 2 that becomes the lead portion 4 at the start of winding is accommodated. The lead guide groove 12 extends from the vicinity of the binding rod 38 to the concave portion 37 so that the wire 2 extending from the binding rod 38 to the winding core 42 is accommodated when the coil portion 3 is wound.

  The lead guide groove 12 has two planar groove side surfaces 13 extending in parallel to a plane including the winding center axis O (the rotation center axis of the second winding jig 35), and the opening width thereof is the wire 2. Is set larger than the outer diameter by a predetermined clearance.

  The lead guide groove 12 has a pair of lead guide groove opening edges 14, and the lead guide groove opening edges 14 define a wedge-shaped gap in cross section where the wire 2 enters between the winding cores 42. As shown in FIGS. 5 (a) and 5 (b), the wire 2 is guided to be pressed against the winding core 42 at the start portion of the wire 2 that becomes the lead base end portion 4a.

  The lead guide groove opening edge 14 is formed to be inclined with respect to the groove side surface 13. In other words, the lead guide groove opening edge portion 14 is inclined with respect to the plane including the winding center axis O, and defines a gap having a wedge-shaped cross section between the winding cores 42.

  Since a pair of lead guide groove opening edges 14 are formed at the opening ends of the lead guide grooves 12, one of the lead guide groove opening edges 14 winds the wire 2 even if the rotation direction of the winding core 42 is changed. 42 is pressed against.

  If the direction of rotation of the winding core 42 is not changed, one lead guide groove opening edge 14 may be formed only on the side where the wire 2 at the opening end of the lead guide groove 12 is wound.

  Further, as the lead portion guiding means, the groove side surface 13 of the lead guide groove 12 may be formed so as to be inclined with respect to a plane including the winding center axis O. In this case, the groove side surface 13 of the lead guide groove 12 defines a wedge-shaped gap in which the wire 2 enters between the cores 42, and the portion that becomes the base end of the lead portion 4 at the start of winding of the wire 2 Guide them to press.

  When the angle of inclination of the wire 2 extending from the binding rod 38 through the lead guide groove 12 to the nozzle 58 in the wire rod winding process with respect to the winding center axis O (X axis) increases, the wire 2 is opened to the lead guide groove. It becomes difficult to engage with the edge 14.

  In response to this, the binding bar 38 is provided at a predetermined distance from the jig end surface 36 (core 42) in the winding center axis O (X axis) direction. The angle at which the wire 2 extending from the bar 38 through the lead guide groove 12 to the core 42 is inclined with respect to the winding center axis O (X axis) is set to be sufficiently small, and the nozzle 58 is moved and entangled. The wire 2 that is wound from the rod 38 through the lead guide groove 12 to the core 42 enters a wedge-shaped gap formed between the lead guide groove opening edge 14 and the core 42. Yes.

  The jig end surface 36 of the second winding jig 35 and the jig end surface 41 of the first winding jig 40 are formed in a planar shape orthogonal to the winding center axis O (X axis).

  The second winding jig 35 is formed with an inclined surface 15 inclined with respect to the winding center axis O (X axis), and the lead guide groove 12 is opened in the inclined surface 15. Due to the inclined surface 15, the portion where the lead guide groove 12 is opened in the second winding jig 35 is tapered, and the wire 2 extending from the binding bar 38 to the nozzle 58 in the wire winding process is used as the lead guide. It is easy to enter the groove 12.

  The controller includes each servo motor of each mobile unit 25, 45, 51, 52, 53, 71, 72, 73, first and second spindle motors 22, 32, coating stripper 59, cylinders 62, 64, cutter 61, The operations of the clamp 84, the cutter 83, etc. are sequence-controlled, and the air core coil 1 is automatically formed by winding the wire 2 around the first and second winding jigs 40, 35.

  The coil winding apparatus 10 performs the following steps in order to form the air-core coil 1. Hereinafter, the operation of the coil winding apparatus 10 will be described with reference to FIGS.

  As shown by the arrow in FIG. 6 (1), the first winding jig 40 is moved closer to the second winding jig 35 by the moving device 25, and the tip end portion 42 a of the winding core 42 is fitted into the recess 37. Let

  At this time, the interval between the jig end surface 41 of the first winding jig 40 and the jig end surface 36 of the second winding jig 35 is set according to the winding width of the air-core coil 1. The interval between the jig end faces 41 and 36 is arbitrarily set within a range larger than the outer diameter of the nozzle 58 so that the nozzle 58 is inserted between the jig end faces 41 and 36.

  As indicated by the arrows in (2), the first and second spindles 20 and 30 rotate the first and second winding jigs 40 and 35 by 90 ° and direct the binding rod 38 toward the nozzle 58.

  (3) As shown by arrows in FIG. 7 (4), the nozzles 58 are moved by the respective mobile units 51, 52, and 53 so that the wire 2 is entangled with the tie rod 38, and from the slit 39 of the tie rod 38. The wire 2 is extended to the nozzle 58. Thereby, the tip of the wire 2 is held at a predetermined position with respect to the second winding jig 35.

  The above operation is performed as a wire end holding step of holding the tip end portion of the wire 2 fed from the nozzle 58 to the wire end holding means (the binding rod 38).

  As indicated by the arrow in (5), the nozzle 58 is moved along the lead guide groove 12 in the X-axis direction.

  As indicated by the arrow in (6), the nozzle 58 is moved in the Y-axis direction, the tip of the nozzle 58 is inserted between the jig end surfaces 41 and 36, and the wire 2 extending from the binding rod 38 to the nozzle 58 is shown. Is passed through the lead guide groove 12.

  The slit 39 of the binding rod 38 is disposed on the extension line of the lead guide groove 12, and the wire 2 extending from the slit 39 to the nozzle 58 enters the lead guide groove 12. The wire rod 2 is not limited to this, and the slit 39 of the binding rod 38 is offset with respect to the extension line of the lead guide groove 12 and is engaged with the slit 39 to extend from the outer periphery of the binding rod 38 to the nozzle 58. May be configured to enter the lead guide groove 12.

  As indicated by an arrow in FIG. 8 (7), the nozzle 58 is moved in the Z-axis direction between the jig end faces 41 and 36, and the wire 2 extending to the nozzle 58 through the lead guide groove 12 is moved to the lead guide groove. A gap having a cross-sectional wedge shape defined between the opening edge 14 and the core 42 is inserted (see FIGS. 5A and 5B).

  At this time, the wire 2 enters the gap having a cross-sectional wedge shape defined between the opening edge 14 of the lead guide groove and the core 42, thereby pressing the wire 2 against the core 42. Try not to lift up.

  The above operation is performed as a winding process in which the wire 2 extending from the wire end holding means (the binding rod 38) to the nozzle 58 is wound around the core 42 through the lead guide groove 12.

  As indicated by the arrows in (8), the first and second spindles 20 and 30 are used to rotate the first and second winding jigs 40 and 35 while winding the wire 2 fed from the nozzle 58 around the core 42. The nozzle 58 is moved in the Y-axis direction so that the tip of the nozzle 58 comes out between the jig end faces 41 and 36.

  Subsequently, the moving device 25 moves the first winding jig 40 so as to approach the second winding jig 35, narrows the distance between the jig end surfaces 41, 36, and the wire 2 wound around the core 42. Is moved along the jig end surface 41. At this time, a gap larger than the outer diameter of the wire 2 by a predetermined clearance is defined between the jig end surfaces 41 and 36, and the first wire 2 is wound with high accuracy.

  As indicated by arrows in (9), the nozzle 58 is moved in the X-axis direction in synchronization with the rotation of the first and second winding jigs 40 and 35, and the first winding jig 40 is moved in the X-axis direction. To do. When the first coil is wound around the core 42, the wire 2 is wound by being guided by the jig end face 41 of the first winding jig 40, and the first winding jig 40 that has already been wound is wound. The wire 2 is wound with high accuracy while being guided by the jig end surface 41.

  While the first layer coil is wound in this way, the wire 2 is guided to the already wound coil and the jig end surface 41 and aligned and wound around the core 42.

  As indicated by arrows in FIG. 9 (10), the first and second winding jigs 40 and 35 are rotated, and the wire 2 fed from the nozzle 58 is passed through the guide rods 65 to pass the wire 2 into the first layer. The coil portion 3 is formed by winding the wire 2 on the coil, winding the wire 2 with the second layer, the third layer, and a predetermined number of turns.

  As shown in (10), when the second layer coil is wound, the wire rod guide 63 is moved to the upper winding position, and the wire rod 2 is passed between the guide rods 65. Each guide bar 65 moves in the Y-axis direction in synchronization with the rotation of the first and second spindles 20 and 30 together with the nozzle 58, accurately guides the wire 2 inserted through each guide bar 65, and winds the wire 2 Even if the speed is increased, the wire 2 can be aligned and wound. The wire 2 may be guided between the guide rods 65 also when the first layer coil is wound.

  The above operation is performed as a winding process in which the coil 42 is formed by rotating the core 42 and winding the wire 2 fed from the nozzle 58 around the core 42.

At this time, the fusion layers coated on the surface of the wire 2 are heated and welded when the coil portion 3 is wound, so that the shape of the coil portion 3 is maintained.
As indicated by the arrow in (11), the first and second winding jigs 40 and 35 are reversely rotated by 180 ° and stopped at a position where the binding rod 38 and the lead guide groove 12 face upward.

  As indicated by the arrow in (12), the forming table 80 is moved to bring the cutter 83 and the clamp 84 closer to the wire 2.

  As shown in FIG. 10 (13), the wire 2 extending from the binding rod 38 to the coil portion 3 is clamped by the clamp 84, and the wire 2 is cut by the cutter 83.

  The above operation is performed as a cutting step of cutting the wire 2 extending from the wire end holding means (the binding rod 38) to the coil portion 3 by the cutter 83.

  The cutter 83 is moved away from the wire 2 as indicated by the arrow in (14).

  As indicated by an arrow in (15), the clamp 84 is moved with an arcuate locus while holding the wire 2.

  As a result, the wire 2 extending from the coil portion 3 is pulled out from the lead guide groove 12, and the wire 2 is bent from the inner peripheral winding portion 3a of the coil portion 3 as shown in FIGS. It extends along the side surface winding part 3b of the part 3, and the winding start lead part 4 is shaped.

  The above operation is performed as a shaping process of the winding start lead portion 4 that moves the clamp 84 to draw out the wire 2 that fits in the lead guide groove 12 and shapes it along the side surface winding portion 3 b of the coil portion 3.

  As indicated by an arrow in FIG. 11 (16), the clamp 84 is moved away from the wire 2, and the nozzle 58 is moved in the Y-axis direction away from the coil portion 3, and the wire 2 is pulled out from the nozzle 58.

  As indicated by arrows in (17), the first and second winding jigs 40 and 35 are rotated in the winding direction by 90 °. Thereby, the winding start lead part 4 extends in the Y-axis direction, and the wire 2 extending from the coil part 3 to the nozzle 58 is loosened.

  As indicated by the arrow in (18), the forming table 80 is moved to bring the forming device 81 closer to the coil unit 3.

  As indicated by an arrow in (19) of FIG. 12, the moving device 25 moves the first winding jig 40 in the direction away from the second winding jig 35 to expose the side winding part 3b of the coil part 3, The forming table 81 is moved to bring the forming device 81 closer to the side surface winding portion 3 b of the coil portion 3.

  As indicated by an arrow in (20), the forming table 80 is moved in the X-axis direction, and the forming plate 88 of the forming device 81 is pressed against the side surface winding portion 3b side of the coil portion 3. At this time, the winding start lead portion 4 is pressed against the side surface winding portion 3b of the coil portion 3 by the forming plate 88, and the fusion layers coated on the surface of the wire 2 are welded together, whereby the winding start lead base end portion 4a. Is fixed to the side surface winding portion 3b of the coil portion 3, and the shape of the lead base end portion 4a at the start of winding is maintained.

  In the state where the forming plate 88 is continuously pressed against the side surface winding portion 3b side of the coil portion 3, as indicated by the arrow in (21), the nozzle 58 is moved in the Y-axis forward direction, the Z-axis upward direction, and the Y-axis backward direction. The winding end lead proximal curved portion 5a extending along the side surface winding portion 3b of the coil portion 3 is formed on the winding end lead portion 5 by shaping the wire rod 2 around the forming pin 82. It is formed.

  The above operation is performed as a shaping step of the winding end lead portion 5 that shapes the wire 2 along the side surface winding portion 3b of the coil portion 3 via the forming pin 82.

  As shown by the arrow in (22) of FIG. 13, the forming device 81 is moved away from the coil unit 3.

  As indicated by the arrow in (23), the cutter 83 is lowered and the wire 2 is cut by the cutter 83 to form the winding end lead portion 5 having a predetermined length.

  As indicated by an arrow in (24), the moving device 25 moves the first winding jig 40 so as to approach the second winding jig 35, and the jig end surface 36 of the second winding jig 35 is moved to the coil portion 3. Press against the side winding 3b side. At this time, the winding end lead portion 5 is pressed against the side surface winding portion 3b of the coil portion 3 by the jig end surface 36, and the fusion layers coated on the surface of the wire 2 are welded to each other. The bending portion 5a is fixed to the side surface winding portion 3b of the coil portion 3, and the shape of the winding end lead proximal end bending portion 5a is maintained.

  The above operation is performed as a pressing process of the winding end lead portion 5 in which the jig end surface 36 of the second winding jig 35 presses and fixes the wire 2 to the side surface winding portion 3b of the coil portion 3.

  As a result, the winding start lead portion 4 and the winding end lead portion 5 are substantially aligned in the radial direction from the winding center axis O of the coil portion 3 as shown in FIGS. It is formed to extend with the same length.

  At the leading end portions of the winding start lead portion 4 and the winding end lead portion 5, the coating layer and the insulating layer are peeled off by the coating peeling machine 59.

  As indicated by an arrow in FIG. 14 (25), the first winding jig 40 is moved away from the second winding jig 35 by the moving device 25, and the ejector 85 is moved closer to the first winding jig 40. .

  As indicated by the arrow in (26), the winding core 42 is pulled out from the jig end surface 41 by the moving device 45, the winding core 42 is extracted from the coil portion 3, and the ejector 85 is moved so as to follow the winding core 42. The rod-shaped tip of the ejector 85 is inserted into the coil portion 3. Thereby, the air-core coil 1 removed from the first winding jig 40 is transferred to the ejector 85.

  The above operation is performed as an extraction process for extracting the core 42 from the coil portion 3.

  The ejector 85 is not limited to this structure, and may be configured to include a suction nozzle that attracts the air-core coil 1 by negative pressure.

  As indicated by an arrow in (27), the ejector 85 that has received the air-core coil 1 is moved, and the air-core coil 1 is hung on a stock rod (not shown) and stocked.

  By performing the above steps in order, the air-core coil 1 is automatically formed, and it becomes unnecessary to manually shape the winding start lead portion 4 and the winding end lead portion 5, thereby improving productivity.

  As shown in FIGS. 1A and 1B, the air-core coil 1 is shaped so that the winding start lead portion 4 and the winding end lead portion 5 extend substantially in parallel with a predetermined interval. The operation of soldering the lead part 4 and the winding end lead part 5 to the substrate is performed efficiently.

  In the winding end lead portion 5, the winding end lead proximal curved portion 5a is bent from the outer peripheral winding portion 3c of the coil portion 3, and is curved and extended along the side surface winding portion 3b of the coil portion 3. Even if the portion 5 is pulled in the outer diameter direction of the coil portion 3, the winding end lead proximal curved portion 5 a is bent and deformed to prevent the outer peripheral winding portion 3 c of the coil portion 3 from being collapsed, and to the wire 2. The disconnection due to excessive stress is prevented, and the shape of the coil portion 3 is maintained.

  On the other hand, as shown in FIG. 15, when the winding end lead portion 5 is bent from the outer circumferential winding portion 3 c of the coil portion 3 and extends in the outer diameter direction of the coil portion 3, the winding end lead portion 5 is If the coil portion 3 is pulled in the outer diameter direction, the outer peripheral winding portion 3c of the coil portion 3 may collapse or the winding end lead portion 5 may be disconnected.

  In the present embodiment, the coil portion 3 in which the wire 2 is wound in a spiral shape, the winding start lead portion 4 made of the wire 2 extending from the inner peripheral winding portion 3 a of the coil portion 3, and the outer peripheral winding portion of the coil portion 3 An air core coil 1 having a winding end lead portion 5 made of a wire 2 extending from 3c, and the winding end lead portion 5 is a side winding portion of the coil portion 3 between the outer circumferential winding portion 3c and the inner circumferential winding portion 3a. The winding end lead proximal curved portion 5a is curved and extended along 3b.

  Moreover, in this embodiment, the coil part 3 by which the wire 2 was wound spirally, the winding start lead part 4 which consists of the wire 2 extended from the inner peripheral winding part 3a of this coil part 3, and the outer periphery of the coil part 3 A coil winding method for forming an air-core coil 1 having a winding end lead portion 5 made of a wire 2 extending from a winding portion 3c, wherein the wire 2 fed from a nozzle 58 is wound around a core 42 and the coil portion 3 is wound. And winding the wire 2 extending from the outer periphery winding portion 3c to bend and extend along the side surface winding portion 3b of the coil portion 3 between the outer periphery winding portion 3c and the inner periphery winding portion 3a. It is configured to perform a shaping process of the winding end lead part 5 that forms the winding end lead base end curved part 5 a and a drawing process of extracting the winding core 42 from the coil part 3.

  Moreover, in this embodiment, the coil part 3 by which the wire 2 was wound spirally, the winding start lead part 4 which consists of the wire 2 extended from the inner peripheral winding part 3a of this coil part 3, and the outer periphery of the coil part 3 A coil winding apparatus 10 that forms an air-core coil 1 having a winding end lead portion 5 made of a wire 2 extending from a winding portion 3c, wherein a nozzle 58 that feeds the wire 2 and a wire 2 fed from the nozzle 58 are provided. A winding step that includes a wound core 42 and a forming device 81 that moves relative to the wound core 42, and forms the coil portion 3 by winding the wire 2 fed from the nozzle 58 around the wound core 42; The wire 2 extending from the outer periphery winding portion 3c is shaped by being wound around the forming device 81, and is bent along the side surface winding portion 3b of the coil portion 3 between the outer periphery winding portion 3c and the inner periphery winding portion 3a. Total A shaping step of the lead portion 5 the winding end forming a lead proximal curved portion 5a winding finish that, to the coil unit 3 configured to perform the extraction process for extracting the winding core 42.

  Based on the above configuration, it is possible to automatically form the air-core coil 1 shaped so that the winding end lead portion 5 follows the side surface winding portion 3b of the coil portion 3, and the winding end lead portion 5 can be manually formed. There is no need to reshape, increasing productivity.

  Even if the winding end lead portion 5 is pulled in the outer diameter direction of the coil portion 3, the winding end lead proximal curved portion 5 a curved along the side surface winding portion 3 b of the winding end lead portion 5 is bent and deformed, whereby the coil While preventing the outer periphery winding part 3c of the part 3 from collapsing, the wire 2 is prevented from being disconnected due to excessive stress, and the shape of the coil part 3 is maintained.

  In the present embodiment, a first winding jig 40 in which the winding core 42 projects from the jig end surface 41 and a second winding jig 35 in which a recess 37 is opened in the jig end surface 36 are provided. The wire 2 fed from the nozzle 58 is wound around the core 42 in a state where the one winding jig 40 and the second winding jig 35 are brought close to each other and the tip portion 42 a of the core 42 is fitted in the recess 37, and the coil portion 3. In the shaping process, the first winding jig 40 and the second winding jig 35 are separated, and the jig end surface 36 of the second winding jig 35 is separated from the side surface winding part 3b of the coil part 3, and then the coil. The wire 2 extending from the outer peripheral winding part 3c of the part 3 is wound around a forming device 81 and shaped.

  Based on the above configuration, the outer peripheral winding portion of the coil portion 3 is wound around the forming device 81 with the jig end surface 36 of the second winding jig 35 separated from the side surface winding portion 3b of the coil portion 3. The wire 2 extending from 3c can be shaped so as to bend and extend along the side surface winding portion 3b of the coil portion 3.

  In the present embodiment, the forming device 81 projects in the direction of the winding center axis O of the coil portion 3 from the forming plate 88 and the plate-shaped forming plate 88 that contacts the side surface winding portion 3b of the coil portion 3 in the shaping process. The rod-shaped forming pin 82 is used.

  Based on the above configuration, after forming the coil portion 3, the nozzle 58 is moved and wound around the forming pin 82 protruding from the forming plate 88 with the forming plate 88 in contact with the side surface winding portion 3 b of the coil portion 3. By winding the wire 2 to be the end lead portion 5, the winding end lead base end curved portion 5a extending in a curved manner along the side surface winding portion 3b of the coil portion 3 can be shaped.

  In the present embodiment, after the shaping process is performed, the first winding jig 40 and the second winding jig 35 are brought close to each other so that the jig end surface 36 of the second winding jig 35 winds the wire 2 on the side surface of the coil portion 3. It is set as the structure which performs the press process of the winding end lead part 5 pressed against the part 3b.

  Based on the above configuration, the end surface 36 of the second winding jig 35 presses the wire 2 against the side surface winding part 3 b of the coil part 3 in the pressing step, so that the winding end lead part 5 becomes the side surface winding part of the coil part 3. 3b can be adhered.

  In this embodiment, it is set as the structure which performs the shaping process of the winding start lead part 4 which shapes the wire 2 extended from the inner peripheral winding part 3a of the coil part 3 so that the side surface winding part 3b of the coil part 3 may be followed.

  Based on the above configuration, it is possible to automatically form the air-core coil 1 shaped so that the winding start lead portion 4 is along the side surface winding portion 3b of the coil portion 3, and the winding start lead portion 4 is manually formed. There is no need to reshape, increasing productivity.

  In this embodiment, the wire rod end holding means (the binding rod 38) that holds the tip of the wire 2 fed from the nozzle 58 to the second winding jig 35, and the wire rod that extends from the wire rod end holding means (the binding rod 38). 2 is provided, and includes a cutter 83 for cutting the wire 2 and a clamp 84 for holding and moving the wire 2, and a tip end of the wire 2 fed out from the nozzle 58 is provided with a wire end holding means ( A wire rod end holding step held by the binding rod 38), a winding step of winding the wire rod 2 extending from the wire rod end holding means (link rod 38) to the nozzle 58 around the winding core 42 through the lead guide groove 12, A winding step of rotating the core 42 to wind the wire 2 fed from the nozzle 58 around the winding core 42 to form the coil portion 3, and the wire 83 from the wire end holding means (the binding rod 38) to the coil portion 3 by the cutter 83. Wire that extends A cutting step of cutting the lead wire 4 which is accommodated in the lead guide groove 12 by moving the clamp 84, and shaping the winding start lead portion 4 to be shaped along the side surface winding portion 3b of the coil portion 3, and the coil The extraction step of extracting the core 42 from the part 3 is performed.

  Based on the above configuration, it is possible to automatically form the air-core coil 1 shaped so that the winding start lead portion 4 is along the side surface winding portion 3 b of the coil portion 3.

  In the present embodiment, the lead guide groove 12 has lead portion guide means (lead guide groove opening edge portion 14) that defines a wedge-shaped gap in which the wire 2 enters between the winding cores 42. The wire rod 2 wound around the core 42 through the lead guide groove 12 engages with the lead portion guide means (lead guide groove opening edge portion 14) to press the proximal end portion of the lead portion 4 against the core 42. The configuration.

  Based on the above configuration, when the wire 2 is engaged with the lead portion guide means (lead guide groove opening edge portion 14), the nozzle 58 is moved to move from the binding rod 38 through the lead guide groove 12 to the core 42. The wire 2 to be wound around is wound without lifting from the core 42, and the wire 2 in the inner peripheral winding portion 3 a of the coil portion 3 is aligned and wound, and the winding start lead portion 4 is connected to the coil portion 3. The space factor of the wire 2 in the air-core coil 1 can be increased by bending from the inner peripheral winding portion 3a and extending along the side surface winding portion 3b of the coil portion 3.

  The present invention is not limited to the above-described embodiment, and it is obvious that various modifications can be made within the scope of the technical idea.

The side view and sectional drawing of the air-core coil which show embodiment of this invention. The perspective view of a winding device similarly. Similarly, the perspective view of a 1st, 2nd winding jig. Similarly, the perspective view of a 1st, 2nd winding jig. Similarly, the perspective view and sectional drawing of a 1st, 2nd winding jig. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The perspective view which similarly shows operation | movement of a winding apparatus. The side view of the air-core coil which shows a comparative example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Air core coil 2 Wire material 3 Coil part 3a Inner circumference winding part 3b Side surface winding part 3c Outer circumference winding part 4 Winding start lead part 4a Winding start lead base part 5 Winding end lead part 5a Winding end lead base curved part 10 Coil winding Wire device 12 Lead guide groove 14 Lead guide groove opening edge (lead portion guide means)
35 Second winding jig 36 Jig end face 37 Concave portion 38 Binding rod (wire end holding means)
40 First Winding Jig 42 Winding Core 58 Nozzle 59 Cover Peeling Machine 81 Forming Device 82 Forming Pin 83 Cutter 84 Clamp 85 Ejector 90 Hot Air

Claims (7)

A coil portion in which a wire is wound in a spiral shape;
A winding start lead portion made of the wire extending from the inner circumferential winding portion of the coil portion; and
An air-core coil having a winding end lead portion made of the wire extending from the outer peripheral winding portion of the coil portion,
The winding end lead portion has a winding end lead proximal curved portion that extends and curves along the side surface winding portion of the coil portion between the inner circumferential winding portion and the outer circumferential winding portion. Core coil. A coil portion in which a wire is wound in a spiral shape;
A winding start lead portion made of the wire extending from the inner circumferential winding portion of the coil portion; and
A coil winding method for forming an air-core coil having a winding end lead portion made of the wire extending from an outer peripheral winding portion of the coil portion,
A winding step of winding the wire fed from the nozzle around a core to form the coil portion;
The wire extending from the outer peripheral winding portion is shaped to form a winding end lead proximal curved portion extending in a curved manner along the side winding portion of the coil portion between the outer peripheral winding portion and the inner peripheral winding portion. The winding end lead shaping process
A winding method of an air core coil, wherein a step of extracting the core from the coil portion is performed. A coil portion in which a wire is wound in a spiral shape;
A winding start lead portion made of the wire extending from the inner circumferential winding portion of the coil portion; and
A coil winding device for forming an air-core coil having a winding end lead portion made of the wire extending from an outer peripheral winding portion of the coil portion,
A nozzle for feeding out the wire,
A core around which the wire drawn from the nozzle is wound;
With a forming device that moves relative to the core,
A winding step of winding the wire fed from the nozzle around a core to form the coil portion;
The wire end extending from the outer peripheral winding portion is shaped by being wound around the forming device, and the winding end is curved and extended between the outer peripheral winding portion and the inner peripheral winding portion along the side surface winding portion of the coil portion. Shaping step of the winding end lead portion forming the lead base end curved portion;
A winding device for an air core coil, characterized in that a step of extracting the core from the coil portion is performed. A first winding jig in which the winding core projects from a jig end surface;
A recess is provided with a second winding jig that opens to the end face of the jig,
In the winding process, the first winding jig and the second winding jig are brought close to each other, and the wire rod fed out from the nozzle in a state where the tip end portion of the winding core is fitted in the recess is used as the winding core. Winding to form the coil part,
In the shaping step, the first winding jig and the second winding jig are separated, and the jig end surface of the second winding jig is separated from the side surface winding part of the coil part. The winding device for an air-core coil according to claim 3, wherein the wire extending from the outer peripheral winding portion is wound around the forming device and shaped. The forming device is a plate-shaped forming plate that contacts the side surface winding portion of the coil portion in the shaping step;
4. The winding device for an air-core coil according to claim 3, further comprising: a rod-shaped forming pin protruding from the forming plate in a winding center axis direction of the coil portion.   After the shaping step is performed, the first winding jig and the second winding jig are brought close to each other, and the jig end surface of the second winding jig presses the wire rod against the side surface winding portion of the coil portion. 6. The winding device for an air-core coil according to claim 4, wherein a pressing process of the winding end lead portion is performed.   The configuration is such that the step of shaping the winding start lead portion for shaping the wire extending from the inner circumferential winding portion of the coil portion so as to follow the side surface winding portion of the coil portion is performed. 6. The winding device for an air-core coil according to any one of 6 above.