JP2020088385A - Non-circular coil manufacturing device, non-circular coil manufacturing method and non-circular coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a non-circular coil manufacturing apparatus, a non-circular coil manufacturing method and a non-circular coil capable of shortening the manufacturing time while improving the workmanship. A non-circular coil manufacturing apparatus includes a winding unit and a molding unit 5 for forming a circular winding portion into a non-circular winding portion. The molding unit 5 has a rod shape and a cross-sectional shape orthogonal to the central axis J1 is similar to the shape inside the non-circular winding portion of the non-circular coil. A punch 52 provided with a small tapered portion 521, a molding tool 51 having two support portions for supporting the circular coil C1 from the −Z direction side, and a punch 52 driven to insert the punch 52 inside the circular winding portion. A support portion drive that drives the two support portions so that the distance between the two support portions in the X-axis direction increases as the punch drive portion 56 and the circular winding portion deform so as to extend in the X-axis direction. It has a part 541 and. [Selection diagram] Fig. 5

Description

The present invention relates to a non-circular coil manufacturing device, a non-circular coil manufacturing method, and a non-circular coil.

A non-circular coil manufacturing apparatus has been proposed that includes a winding machine that winds a wire rod in a circle to obtain a circular coil, and a molding machine that molds the circular coil into a non-circular coil (see, for example, Patent Document 1). In this non-circular coil manufacturing apparatus, when a circular coil is formed into a non-circular coil, a step of intruding a pair of expanding members inside the circular coil, and gripping the pair of expanding members and the circular coil from the outside Two steps, that is, a step of widening the interval between the pair of expanding members with the circular coil sandwiched by the pair of gripping pieces, are performed.

JP2012-004482A

However, in the non-circular coil manufacturing apparatus described in Patent Document 1, it is necessary to perform two steps of forming a circular coil by a winding machine and forming a circular coil into a non-circular coil by a forming machine. There is a limit to the reduction of the manufacturing time required to manufacture one non-circular coil.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a non-circular coil manufacturing apparatus, a non-circular coil manufacturing method, and a non-circular coil that can improve the quality and shorten the manufacturing time.

In order to achieve the above object, the non-circular coil manufacturing device according to the present invention,
A winding unit that winds a wire rod in a circle to form a circular winding portion that is circular in plan view on the wire rod,
A molding unit for molding the circular winding portion into a non-circular winding portion having a non-circular shape in plan view,
The molding unit is
The cross-sectional shape that is rod-shaped and orthogonal to the central axis is a similar shape to the shape inside the non-circular winding portion, and the area of the cross-section orthogonal to the central axis is smaller toward the first direction side along the stretching direction, and at least the above A punch provided with a taper portion having a maximum width in a direction orthogonal to the central axis at an end portion on the first direction side, the taper portion being smaller than an inner diameter of the circular winding portion,
Two support portions that support the circular winding portion from the first direction side,
A punch driving unit that drives the punch in the first direction side and inserts the punch into the inside of the circular winding unit from the end portion in the first direction side;
As the circular winding portion is deformed so as to extend in the second direction orthogonal to the first direction, the two support portions are arranged so that the distance between the two support portions in the second direction expands. A supporting unit driving unit for driving.

According to the present invention, as the support driving unit is deformed so that the punch is inserted inside the circular winding unit and the circular winding unit extends in the second direction, the second driving unit of the two supporting units is changed. The two supports are driven so that the distance in the direction increases. As a result, the ratio of the portion supported by the two supporting portions in the circular winding portion and the non-circular winding portion formed by deforming the circular winding portion so as to extend in the second direction is maintained at a preset ratio or more. can do. Therefore, when the punch is inserted inside the circular coil, occurrence of distortion in the first direction of the non-circular winding portion due to the force applied to the circular winding portion in the first direction is suppressed, and the non-circular coil Can improve the workmanship of. Further, according to the present invention, the non-circular coil can be produced only by the step of inserting the punch inside the circular winding portion. Therefore, for example, after the circular coil is obtained by the above-described winding machine, it is transferred to the molding machine, and after performing the step of inserting the pair of expanding members into the inside of the circular coil, the interval between the pair of expanding members is changed. It is possible to reduce the manufacturing time of the non-circular coil as compared with the configuration in which the expanding step is performed.

FIG. 3 is a schematic plan view of the non-circular coil manufacturing device according to the first embodiment of the present invention. The non-circular coil manufacturing apparatus which concerns on Embodiment 1 is shown, (A) is a schematic front view which shows the state before conveying a wire rod to a winding unit, (B) is after conveying a wire rod to a winding unit. It is a schematic front view which shows the state of. The tension|tensile_strength application part of the wire rod conveyance unit which concerns on Embodiment 1 is shown, (A) is a schematic side view, (B) is a schematic side view when the wire rod M is pulled out, (C) is (A). It is a schematic side view showing a state in which the pressing force of the wire rod is increased as compared with the case of. FIG. 3 shows a part of the winding unit according to the first embodiment, (A) is a schematic side view, and (B) is a partially cutaway schematic bottom view. FIG. 3 is a schematic front view of the molding unit according to the first embodiment. FIG. 4 is a schematic perspective view showing a part of the molding unit according to the first embodiment, (A) showing a state before inserting the punch inside the circular coil, and (B) inserting the punch inside the circular coil. It is a schematic perspective view which shows the state which was done. (A) is a schematic front view showing how the non-circular coil manufacturing device according to the first embodiment obtains a circular coil, and (B) shows how the winding unit according to the first embodiment obtains a circular coil. It is the schematic bottom view which partially fractured. The non-circular coil manufacturing apparatus which concerns on Embodiment 1 is shown, (A) is a schematic front view which shows the state which the conveyance unit moved to the standby position, (B) is a schematic which shows a mode that a circular coil is cut|disconnected from a wire rod. It is a front view. (A) is a schematic sectional view showing a state immediately before the punch of the forming unit according to the first embodiment is inserted inside the circular coil, and (B) is a circular punch of the forming unit according to the first embodiment. It is a schematic sectional drawing which shows the state inserted in the inside of a coil. FIG. 3A is a schematic cross-sectional view showing a state immediately before a punch is inserted inside a circular coil in the forming unit according to the first embodiment, and FIG. 3B is a part of the forming unit according to the first embodiment. FIG. 6 is a schematic plan view showing a state immediately before the punch is inserted inside the circular coil, and (C) is a schematic cross-sectional view showing a state where the punch is inserted inside the circular coil in the molding unit according to the first embodiment. Is. An example of the non-circular coil produced by the non-circular coil manufacturing device according to the first embodiment is shown, (A) is a schematic plan view, and (B) is a schematic side view. It is a schematic front view of the non-circular coil manufacturing apparatus which concerns on Embodiment 2 of this invention. (A) is a front view showing a part of the coil holding unit according to the second embodiment, and (B) is a perspective view showing a part of the cutting unit according to the second embodiment. FIG. 9 is a schematic perspective view showing a state where a wire is held in the coil holding unit according to the second embodiment. (A) is a schematic perspective view showing a state immediately before the punch of the molding unit according to the second embodiment is inserted inside the winding portion, and (B) is a perspective view of the punch of the molding unit according to the second embodiment. It is a schematic perspective view which shows the state isolate|separated from the winding part. FIG. 9 is a schematic perspective view showing a state in which the cutting unit according to the second embodiment is arranged near the winding portion of the wire. (A) is a schematic perspective view showing a state where the projection of the cutting unit according to the second embodiment is fitted in the groove of the coil holding unit, and (B) cuts the wire rod in the cutting unit according to the second embodiment. It is a schematic sectional drawing which shows the state just before. FIG. 9 is a schematic cross-sectional view showing a state after cutting the wire rod in the cutting unit according to the second embodiment. An example of the non-circular coil produced by the non-circular coil manufacturing device according to the second embodiment is shown, (A) is a schematic plan view, and (B) is a schematic side view.

(Embodiment 1)
Hereinafter, a non-circular coil manufacturing device according to an embodiment of the present invention will be described with reference to the drawings. The non-circular coil manufacturing device according to the present embodiment is a device for manufacturing a non-circular coil in which a part of a wire having a rectangular cross section is wound in a non-circular shape. This non-circular coil manufacturing device includes a winding unit that winds a wire into a circular shape to obtain a circular coil, and a molding unit that shapes the circular coil into a non-circular coil having a different shape from the circular shape. Then, the forming unit inserts a punch into the circular coil supported by the two supporting portions to form the circular coil into a non-circular coil.

As shown in FIG. 1, the non-circular coil manufacturing device according to the present embodiment includes a wire rod carrying unit 2, a winding unit 3, a coil holding unit 4, a forming unit 5, and a heating unit 6. .. Further, the non-circular coil manufacturing device includes a transport unit 7 that transports the forming unit 5 in the X-axis direction, and a transport unit 8 that transports the heating unit 6 in the X-axis direction. Further, the non-circular coil manufacturing device includes a blower (not shown) that blows air to the produced non-circular coil to blow the non-circular coil toward the product recovery unit (not shown). As the wire rod M supplied to the wire rod transport unit 2, for example, a so-called rectangular copper wire in which a coating layer is coated on the outside of a copper core wire having a rectangular cross section is adopted. As a material for forming the coating layer, for example, a thermoplastic resin having electrical insulation is adopted. The wire M has a width of, for example, 0.5 mm or less and a thickness of 55 μm or less. As the wire material M, for example, a rectangular wire having a width of 0.3 mm and a thickness of 45 μm is adopted.

As shown in FIGS. 1 and 2A, the wire rod transport unit 2 includes a holding portion 23, guide rollers 221, 222, a tension applying portion 21, a holding portion 23, guide rollers 221, 222, and a tension applying portion. A support base 24 that collectively supports 21 and a support base drive unit 25 that drives the support base 24 are provided. As shown in FIG. 2A, the holding portion 23 has an insertion hole 23a through which the wire M is inserted. The holding portion 23 is held in a state in which the holding target portion Mb of the wire M, which is separated from the tip end Ma of the wire M by a distance corresponding to a length required for producing one non-circular coil, is inserted into the insertion hole 23a. To do. The guide rollers 221 and 222 are located on the upstream side of the wire rod M with respect to the holding portion 23 and guide the wire rod M to the holding portion 23. Here, the two guide rollers 222 are in contact with the wire rod M from the +Z direction side, and the guide rollers 221 are in contact with the wire rod M from the −Z direction side.

The tension applying unit 21 includes a pressing claw 211 that presses the wire rod M at its tip, a shaft 212, and a pressing force adjusting unit 213 that adjusts the pressing force that presses the wire rod M by the pressing claw 211. The tension applying section 21 applies a tension to the wire M by bringing the tip of the pressing claw 211 into contact with the wire M and pressing the wire M in the −Z direction. The shaft portion 212 is fixed to the support base 24. The pressing claw 211 has a base end portion axially supported by a shaft portion 212 and is rotatable about a rotation axis J13. The tip of the pressing claw 211 is in contact with the wire M from the +Z direction side. As shown in FIG. 3A, the pressing force adjusting portion 213 includes a main body portion 2131 fixed to the support base 24, two coil springs 2132A and 2132B, and an urging force applied to the pressing claw 211 by the coil springs 2132A and 2132B. And adjusting screws 2133A and 2133B for adjusting. The main body portion 2131 is recessed in the −X direction side, and the recess 2131 a in which the base end portion of the pressing claw 211 is disposed and the screw extending in the Y axis direction on each side of the recess 2131 a in the main body portion 2131 in the Y axis direction. And holes 2131b and 2131c.

The coil spring 2132A has an end on the −Y direction side inserted inside the screw hole 2131b, and an end on the +Y direction side protrudes from the screw hole 2131b to the inside of the recess 2131a. Further, in the coil spring 2132A, the end portion on the +Y direction side is inserted inside the screw hole 2131c, and the end portion on the −Y direction side projects from the screw hole 2131c to the inside of the recess 2131a. As indicated by an arrow AR105, the coil spring 2132A urges the pressing claw 211 in the first rotation direction in which the tip end of the pressing claw 211 is pressed against the wire M with the base end (shaft 212) as a fulcrum. 1 biasing member. On the other hand, in the coil spring 2132B, the pressing claw 211 is moved in a second rotation direction in which the tip end of the pressing claw 211 separates from the wire M with the base end portion (shaft portion 212) as a fulcrum, that is, the rotation direction indicated by an arrow AR105. Is a second biasing member that biases in the opposite direction.

The adjusting screw 2133A is screwed into the screw hole 2131b from the −Y direction side, and the adjusting screw 2133B is screwed into the screw hole 2131c from the +Y direction side. The adjusting screw 2133A is a first adjusting portion for adjusting the urging force (first urging force) of the coil spring 2132A, and the adjusting screw 2133B adjusts the urging force (second urging force) of the coil spring 2132B. It is a second adjusting unit for doing.

When the wire M is pulled out in the +Y direction as shown by an arrow AR106 in FIG. 3B, the pressing claw 211 is tilted as shown by an arrow AR107. As a result, the wire M is smoothly pulled out in the +Y direction. Further, the spring pressure of each of the coil springs 2132A and 2132B can be adjusted by changing the lengths L21 and L22 of the portions screwed into the screw holes 2131b and 2131c of the adjustment screws 2133A and 2133B, respectively. For example, as shown in FIG. 3(C), the length L21 of the screwing portion of the adjusting screw 2133A with the screw hole 2131b is made longer than the length L21 shown in FIG. 3(A) to adjust the adjusting screw 2133B. It is assumed that the length L22 of the screwed portion with the screw hole 2131c is shorter than the length L22 shown in FIG. In this case, the spring pressure of the coil spring 2132A increases and the spring pressure of the coil spring 2132B decreases, and the urging force that urges the pressing claw 211 in the direction indicated by the arrow AR105 increases. As a result, the force with which the pressing claw 211 presses the wire M increases, and the tension applied to the wire M increases.

The support base drive unit 25 includes a guide rail (not shown) extending along the Y-axis direction, a slide body (not shown) movable along the guide rail, and a drive for driving the slide body. And a mechanism (not shown). A support base 24 is fixed to the slide body. The support base drive unit 25 moves the slide body in the Y-axis direction to move the entire support base 24 fixed to the slide body along the Y-axis direction.

As shown in FIG. 1 and FIG. 2A, the winding unit 3 has a long and thin cylindrical core 32 having a reduced diameter at its tip and a cylindrical pedestal in which the core 32 is planted. It has a portion 33 and a cored bar driving portion 35 for rotating the pedestal part 33 around the central axis J0 of the cored bar 32 and moving up and down the cored bar 32 and the pedestal part 33. The winding unit 3 also includes a stage 31 having a recess 311 having an inner diameter long enough to allow the core 32 to be inserted therein, and a stage drive unit 34 for moving the stage 31 up and down. As shown in FIGS. 4A and 4B, a protruding claw portion 331 is provided at the end portion of the pedestal portion 33 on the −Z direction side. Here, when viewed from the −Z direction side, the distance between the side surface of the cored bar 32 and the claw portion 331 is set to be substantially equal to the width of the wire material M. Further, a flat surface 33a including an area between the core metal 32 on which the wire M is placed and the claw portion 331 is formed at the end portion of the pedestal portion 33 on the −Z direction side. Further, the end portion of the pedestal portion 33 on the −Z direction side is inclined with respect to the flat surface 33a in order to avoid interference with the end portion of the wire M wound around the core metal 32 on the winding start side. A section 332 is provided. Further, on the core metal 32 side of the claw portion 331, a tapered surface 331a inclined with respect to a normal direction orthogonal to the flat surface 33a of the pedestal portion 33 is formed. The inclination angle θ1 of the tapered surface 331a with respect to the normal direction orthogonal to the flat surface 33a is set to, for example, 15°±1°. The height H1 of the claw portion 331 in the Z-axis direction is set within the range of 40 μm to 45 μm, for example. The winding unit 3 inserts the core metal 32 into the recess 311 of the stage 31 while holding a part of the wire M between the claw portion 331 of the pedestal portion 33 and the core metal 32, and the core metal driving unit. The cored bar 32 and the pedestal portion 33 are rotated by 35 around the central axis J0 of the cored bar 32 (see, for example, an arrow AR13 in FIG. 4B). As a result, the wire M is wound around the core 32, and a circular winding portion having a circular shape in plan view is formed at the tip of the wire M.

As shown in FIG. 5, the coil holding unit 4 includes a lower tool 41, an upper tool 42, a cutter 43, a cutter drive unit 44 that drives the cutter 43, and a tool drive unit 45 that drives the upper tool 42. Have. The +Z direction side end of the lower tool 41 is provided with a step having a height corresponding to the thickness of the non-circular coil to be manufactured in the winding axis direction. A similar step is also provided on the −Z direction side end of the upper tool 42. Then, in the +Z direction side end portion of the lower tool 41 and the −Z direction side end portion of the upper tool 42, the −Z direction side end surface and the +Z direction side end surface can be brought into surface contact with each other. In the coil holding unit 4, the tool driving unit 45 is mounted in a state in which the wire rod M having a circular winding portion having a circular shape in plan view formed at the tip portion by the winding unit 3 is placed on the +Z direction side end portion of the lower tool 41. The upper tool 42 is brought into contact with the lower tool 41, thereby sandwiching the wire M. The coil holding unit 4 has a circular winding portion by cutting the wire M by moving the cutter 43 in the +Z direction by the cutter driving unit 44 while the wire M is held between the lower tool 41 and the upper tool 42. Generate a circular coil.

As shown in FIG. 5, the molding unit 5 has a rod-shaped punch 52 and a cylindrical base portion 53 in which the punch 52 is implanted. The forming unit 5 also includes a support plate 55 that supports the base portion 53, a punch drive unit 56 that moves the punch 52 by moving the support plate 55 up and down, a forming tool 51, the forming tool 51, and a punch drive unit. And a support base 54 that supports 56. Further, the molding unit 5 includes a pressing member 57 that presses the circular coil C1 from the +Z direction side, and a coil spring 58 that applies a pressure in the −Z direction to the pressing member 57. Here, the punch driving unit 56 drives the punch 52 in the −Z direction (first direction) side and inserts the punch 52 from the −Z direction side end into the circular winding portion of the circular coil. In the forming unit 5, as shown by an arrow AR24 in FIG. 6A, the forming tool 51 is located on the −Z direction side of the circular coil from the −X direction side of the circular coil C1 held by the coil holding unit 4 and punched. 52 is moved so as to be located on the +Z direction side of the circular coil. Then, the forming unit 5 inserts the punch 52 into the inside of the circular winding portion of the circular coil C1 placed on the forming tool 51 to form the circular coil C1 as shown by an arrow AR25 in FIG. 6B. A non-circular coil having a non-circular winding portion that is circular in plan view is formed.

The punch 52 is similar in shape to the inner shape of the non-circular winding portion of the non-circular coil whose cross-sectional shape orthogonal to the central axis J1 is to be produced, and is closer to the central axis J1 toward the -Z direction (first direction). A tapered portion 521 having a small cross-sectional area is provided. The maximum width W1 of the end portion of the punch 52 on the −Z direction side in the direction orthogonal to the central axis J1 is smaller than the inner diameter W2 of the circular winding portion of the circular coil. The molding tool 51 has two support parts 511 and 512, as shown in FIG. The two support portions 511 and 512 support the circular winding portion of the circular coil from the −Z direction side as shown in FIG. 6(B). The two support parts 511 and 512 are arranged so as to face each other in the X-axis direction.

The pressing member 57 presses the circular coil C1 from the −Z direction side in a state where the circular winding portion of the circular coil C1 is supported on the +Z direction side of the two support portions 511 and 512, whereby the two supporting portions 511 are pressed. And 512, the circular winding part of the circular coil C1 is clamped. The pressing member 57 is connected to the support plate 55 via a coil spring 58. Further, a through hole 571 into which the tip portion of the punch 52 is inserted is formed in a portion of the pressing member 57 facing the tip portion of the punch 52. As a result, the punch 52 is guided to the inside of the circular winding portion of the circular coil C1 by the through hole 571, so that when the punch 52 is moved to the −Z direction side, the tip portion thereof smoothly inside the circular coil C1. Is inserted into. A recess 572 is formed on the pressing member 57 on the −Z direction side of the through hole 571. The area of the recess 572 when viewed from the Z-axis direction is set to be larger than the area of the circular winding portion of the circular coil C1. The width H2 of the recess 572 in the Z-axis direction is set to be slightly smaller than the thickness of the circular winding portion of the circular coil C1 to be manufactured in the winding axis direction. The peripheral portion of the through hole 571 on the +Z direction side of the recess 572 of the pressing member 57 corresponds to the contact portions 57a and 57b that contact the circular coil C1 when the circular coil C1 is formed into a non-circular coil.

The support portion 511 has a first mounting surface 511b on which a part of the circular coil C1 is mounted, and a first mounting surface 511b that extends orthogonally to the first mounting surface 511b and extends from the first mounting surface 511b side in the −Z direction. A first support portion having a groove 511a and a first facing surface 511c facing the support portion 512. The support portion 512 has a second mounting surface 512b on which a part of the circular coil C1 is mounted, and a second mounting surface 512b that extends perpendicularly to the second mounting surface 512b and extends in the −Z direction from the second mounting surface 512b side. A second supporting portion having a groove 512a and a second facing surface 512c facing the supporting portion 511. The position of the first groove 511a and the position of the second groove 512a coincide with each other in the Y-axis direction (third direction). In addition, the first groove 511a and the second groove 512a are located inside the first groove 511a in the X-axis direction (second direction) and the second groove 512a with the first facing surface 511c and the second facing surface 512c in contact with each other. The longest distance W3 between the groove 512a and the inside of the groove 512a is formed to be equal to or less than the inner diameter W2 of the circular coil.

In FIGS. 5 and 6, the support base 54 is provided with a support unit drive unit 541 that drives the two support units 511 and 512 toward or away from each other in the Y-axis direction. The support portion drive portion 541 moves as the circular winding portion of the circular coil C1 is deformed so as to extend in the Y-axis direction by inserting the punch 52 inside the circular winding portion of the circular coil C1. The support portions 511 and 512 are driven so that the distance between the two support portions 511 and 512 in the Y-axis direction increases.

Returning to FIG. 1, the heating unit 6 configures the circular winding portion of the circular coil by heating the circular winding portion of the circular coil before the circular winding portion of the circular coil is deformed by the forming unit 5. The film is melt-fixed. The heating unit 6 includes, for example, a hot air blower 61 and a nozzle 62 for adjusting a hot air flow supplied from the hot air blower 61. The heating unit 6 is not limited to the one including the hot air fan 61 and the nozzle 62, and may have another structure such as a heat ray heater or an infrared heater.

The transport unit 7 has a long coil spring 72 whose one end in the longitudinal direction is connected to the support base 54 and the other end is connected to the fixing member 73, and a cam 74 which contacts the support base 54. Further, the transport unit 7 includes a rail (not shown) extending in the X-axis direction, a slide body (not shown) movable along the rail and having a support base 54 fixed to the +Z direction side. Have. The coil spring 72 biases the support base 54 in the +X direction. When the cam 74 rotates about the rotation axis J11 as shown by an arrow AR101 in FIG. 1, the support base 54 moves in the +X direction by the urging force of the coil spring 72 or the −X direction by the cam 74. It is pushed out to.

The transport unit 8 has a rail (not shown) extending in the X-axis direction, a slide body 81 that is movable along the rail and has the heating unit 6 fixed to the +Z direction side, and is long and long. Has a coil spring 82 whose one end is connected to the slide body 81 and the other end is connected to the fixing member 83, and a cam 84 which abuts on the slide body 81. The coil spring 82 biases the slide body 81 in the +X direction. When the cam 84 rotates about the rotation axis J12, as shown by the arrow AR102 in FIG. 1, the slide body 81 moves in the +X direction by the urging force of the coil spring 82 or the −X direction by the cam 84. It is pushed out to.

Next, the operation of the non-circular coil manufacturing device according to this embodiment will be described. First, as shown in FIG. 2(A), in the wire rod transport unit 2, the holding portion 23 has a distance from the tip Ma of the wire rod M, which corresponds to the length required for producing one non-circular coil. It is assumed that the holding target portion Mb spaced apart from each other is held. At this time, the support base 24 is assumed to be located at the standby position Pos0. Here, the wire M is in a state where tension is applied by the pressing claw 211. Next, in the wire rod transport unit 2, as shown by an arrow AR11 in FIG. 2B, the support base 24 is arranged in the winding unit 3 from the standby position Pos0 in a portion corresponding to the circular coil in the wire rod M. To the first position Pos1. At this time, a part of the wire rod M is placed on the stage 31 of the winding unit 3.

Subsequently, as shown by an arrow AR12 in FIG. 7A, in the winding unit 3, the core bar driving unit 35 lowers the core bar 32 and the pedestal part 33 in the −Z direction, so that the core bar 32 is removed. It is inserted into the recess 311 of the stage 31. At this time, as shown in FIG. 4B, a part of the wire material M is fitted between the core metal 32 and the claw portion 331. After that, as shown by an arrow AR13 in FIG. 7B, the core metal driving unit 35 rotates the core metal 32, so that the wire M is wound around the core metal 32. Then, the core bar driving unit 35 stops the rotation of the core bar 32 when the wire M is wound around the core bar 32 by a preset number of turns. At this time, the cored bar driving unit 35 stops the rotation of the cored bar 32 in a state where the tip of the wire M extends in the −Y direction.

Next, as shown by an arrow AR14 in FIG. 8(A), in the coil holding unit 4, the tool driving unit 45 drives the upper tool 42 in the −Z direction, so that the wire M is moved to the lower tool 41 and the upper tool. It is clamped by 42. Subsequently, as shown by an arrow AR15, the support base driving unit 25 corresponds to the length required for producing one circular coil C1 from the cutting portion Mc that cuts the circular coil C1 from the wire M by the holding unit 23. The support base 24 is moved to a standby position (second position) Pos0 capable of holding the holding target portion Mb separated by the distance L1. At this time, since the holding force of the wire rod M in the coil holding unit 4 is stronger than the biasing force of the holding claw 211, the holding claw 211 tilts in the direction shown by the arrow AR16, and the support base 24 receives the resistance of the wire rod M. You can move in the -Y direction without moving. Further, as shown by an arrow AR17 in FIG. 8A, in the winding unit 3, the core bar driving unit 35 raises the core bar 32 and, as shown by an arrow AR18 in FIG. The drive unit 34 lowers the stage 31 in the −Z direction. At this time, a space having a size capable of disposing the molding unit 5 is formed between the stage 31 and the −Z direction side end of the cored bar 32.

Subsequently, as shown by an arrow AR19 in FIG. 8A, in the coil holding unit 4, the cutter driving unit 44 moves the cutter 43 in the +Z direction so that the tip end of the cutter 43 moves to the cutting site Mc of the wire M. Press down. As a result, as shown in FIG. 8(B), the portion corresponding to one circular coil C1 is cut from the wire M.

After that, as shown by an arrow AR101 in FIG. 1, the transport unit 7 rotates the cam 74 to move the support base 54 in the +X direction (see an arrow AR103). As a result, the molding unit 5 moves to the space between the stage 31 and the −Z direction end of the cored bar 32. At this time, as shown in FIG. 6A, the forming tool 51 of the forming unit 5 is inserted from the −X direction side of the circular coil C1 held by the coil holding unit 4 to the −Z direction side of the circular coil C1. It The punch 52 of the forming unit 5 is inserted from the −X direction side of the circular coil C1 held by the coil holding unit 4 to the +Z direction side of the circular coil C1. Further, as shown by an arrow AR102 in FIG. 1, the transport unit 8 moves the slide body 81 in the −X direction by rotating the cam 84 (see an arrow AR104). As a result, the tip of the nozzle 62 of the heating unit 6 is placed at a position where hot air can be applied to the circular winding portion of the circular coil C1.

Next, the heating unit 6 applies hot air to the circular winding portion of the circular coil C1 to heat the circular winding portion of the circular coil C1 and melt and fix the coating film forming the circular winding portion of the circular coil C1. Let Subsequently, while heating the circular winding portion of the circular coil C1 by the heating unit 6, as shown by an arrow AR20 in FIG. 8B, in the forming unit 5, the punch driving unit 56 causes the punch 52 to move the punch 52 in the −Z direction. The taper part 521 of the punch 52 is moved closer to the circular coil C1. At this time, as shown in FIG. 9A, the pressing member 57 also approaches the circular coil C1, and the circular winding portion of the circular coil C1 enters the inside of the recess 572 of the pressing member 57. Then, the punch driving unit 56 further drives the punch 52 in the −Z direction. Then, as shown by an arrow AR26 in FIG. 10A, the +Z direction side of the circular winding portion of the circular coil C1 is pressed toward the −Z direction by the pressing member 57, and the −Z direction side of the punch 52 is pressed. The end of the punch 52 is inserted into the circular winding portion of the circular coil C1. At this time, as shown in FIG. 10(B), of the outer peripheral portion of the through hole 571 of the pressing member 57, the contact portions 57a and 57b located on both sides of the through hole 571 in the Y-axis direction form the circular coil C1. They are in contact with each other. As described above, since the circular coil C1 is pressed by the pressing member 57 and the circular coil C1 is sandwiched between the pressing member 57 and the two supporting portions 511 and 512, the punch 52 is circularly wound around the circular coil C1. The deformation of the circular coil C1 in the Z-axis direction when being inserted inside the portion is suppressed.

Then, as shown in FIG. 9B, the punch driving unit 56 further drives the punch 52 in the −Z direction to cause the punch 52 to enter the inside of the circular winding portion of the circular coil C1. At this time, the circular winding portion of the circular coil C1 has a non-circular winding portion that is deformed so as to extend in the X-axis direction (second direction), as shown by an arrow AR27 in FIG. A circular coil C2 is generated. Here, as shown by an arrow AR28 in FIG. 10(C), the support portion driving portion 541 changes the circular winding portion of the circular coil C1 into the non-circular winding portion of the non-circular coil C2. The two support parts 511, 512 are driven so that the distance between the two support parts 511, 512 in the X-axis direction increases. In this manner, the non-winding portion having the winding portion 102 and the two lead portions 101 extending from both ends in the extending direction of the winding portion 102, as shown in FIGS. 11A and 11B, for example, are provided. A circular coil 100 is produced. Here, the non-circular winding portion 102 and the lead portion 101 are formed, for example, in a rectangular cross section. After that, in the coil holding unit 4, the blower blows air to the produced non-circular coil 100 to direct the non-circular coil to the product recovery unit while the tool driving unit 45 raises the upper tool 42 in the +Z direction. Blow it away.

As shown in FIGS. 11A and 11B, the non-circular coil 100 manufactured by the series of steps described above has a p-direction (fourth direction) orthogonal to the winding axis J2 of the non-circular winding portion 102. The first inner diameter W11 is longer than the second inner diameter W12 in the q direction (fifth direction) orthogonal to the winding axis J2 and the p direction. Further, each of the non-circular winding portion 102 and the lead portion 101 has a width of 0.5 mm or less and a thickness of 55 μm or less. Furthermore, the first inner diameter W11 is set to 1.5 mm or less. As this non-circular coil 100, for example, the first inner diameter W11 is 1.2 mm and the second inner diameter W12 is 0.7 mm. The length W13 of the non-circular coil 100 in the longitudinal direction can be set to 8 to 9 mm. Further, the number of windings of the non-circular winding portion 102 can be set to, for example, 6 to 7 turns, and in this case, the thickness W14 of the non-circular winding portion 102 is set to 0.3 to 0.4 mm. You can

As described above, according to the non-circular coil manufacturing device according to the present embodiment, the support drive unit 541 inserts the circular shape of the circular coil C1 of the punch 52 inside the circular winding section of the circular coil C1. As the winding part is deformed so as to extend in the X-axis direction, the two support parts 511, 512 are driven so that the distance between the two support parts 511, 512 in the X-axis direction increases. Thus, the two support portions 511 in the non-circular coil C2 having the circular winding portion of the circular coil C1 and the non-circular winding portion formed by deforming the circular winding portion of the circular coil C1 so as to extend in the X-axis direction, The proportion of the portion supported by 512 can be maintained above a preset proportion. Therefore, when the punch 52 is inserted into the circular winding portion of the circular coil C1, the non-circular coil C2 is prevented from being distorted in the −Z direction due to the force applied to the circular coil C1 in the −Z direction. Thus, the quality of the non-circular coil 100 can be improved. Further, according to the non-circular coil manufacturing device according to the present embodiment, the non-circular coil 100 can be manufactured only by the step of inserting the punch 52 inside the circular winding portion of the circular coil C1. Therefore, for example, as compared with the configuration in which the step of inserting the pair of expanding members into the inside of the circular winding portion of the circular coil C1 is performed and then the step of expanding the interval between the pair of expanding members is performed, The manufacturing time can be shortened.

By the way, in the conventional method for manufacturing a non-circular coil, it is general that the step of forming the circular coil C1 and the step of molding the circular coil C1 into the non-circular coil 100 are performed by separate devices. On the other hand, in the non-circular coil manufacturing device according to the present embodiment, one process cycle including a process of generating the circular coil C1 and a process of molding the circular coil C1 into the non-circular coil 100 is performed in one process cycle. Since it can be completed in the apparatus, the number of apparatuses required for manufacturing the non-circular coil can be reduced.

Further, as a method of manufacturing the non-circular coil 100 according to the comparative example, there is a method of forming a non-circular coil by compressing from the outside of the circular coil in a direction orthogonal to the winding axis of the circular coil. However, according to this manufacturing method, there is a high possibility that the wound portion will be deformed and stable non-circular shape cannot be formed, and the manufacturing yield of the non-circular coil 100 is low. On the other hand, in the method for manufacturing the non-circular coil 100 according to the present embodiment, the punch 52 is inserted inside the circular winding portion of the circular coil C1 and pushed outward from the inside of the circular coil C1. The circular coil 100 is formed. Therefore, as compared with the method for manufacturing the non-circular coil 100 according to the comparative example, the occurrence of buckling of the non-circular winding portion during manufacturing is reduced, which is advantageous in that the manufacturing yield of the non-circular coil 100 is high.

Further, the first groove 511a and the second groove 512a of the support portions 511, 512 according to the present embodiment are the first in the X-axis direction when the first facing surface 511c and the second facing surface 512c are in contact with each other. The longest distance W3 between the inside of the groove 511a and the inside of the second groove 512a is formed to be equal to or less than the inner diameter W2 of the circular coil C1. Accordingly, when the punch 52 is inserted into the circular coil C1 inside, the ratio of the portion of the circular coil C1 supported by the two supporting portions 511 and 512 can be increased. The occurrence of distortion in the −Z direction of the non-circular coil C2 due to the force applied in the Z direction is suppressed.

Further, the wire rod transport unit 2 according to the present embodiment has a tension applying section 21 that applies tension to the wire rod M supplied from the outside. Thereby, when the wire rod M is wound around the core metal 32 to generate a circular coil, so-called back tension can be continuously applied to the wire rod M. Therefore, when the wire rod M is pulled out from the holding portion 23, there is an advantage that the wire rod M is prevented from being pulled out excessively. In addition, the wire rod transport unit 2 has guide rollers 221 and 222 that are located on the upstream side of the wire rod M with respect to the holding portion 23 and that guide the wire rod M to the holding portion 23. As a result, the bending of the wire M in the wire transport unit 2 is suppressed, so that there is an advantage that the wire M is smoothly supplied to the holding portion 23.

In addition, the heating unit 6 according to the present embodiment starts heating the circular winding portion of the circular coil C1 before the circular coil C1 is transformed into the non-circular coil C2 by the forming unit 5, and thereby the circular coil C1 is heated. The coating film forming C1 and the non-circular coil C2 is melted and fixed. As a result, it is possible to prevent the winding portion from deforming and collapsing when the circular coil C1 is deformed to the non-circular coil C2. Therefore, the quality of the manufactured non-circular coil 100 can be improved.

(Embodiment 2)
The non-circular coil manufacturing device according to the present embodiment is different from that of the first embodiment in that a portion corresponding to one non-circular coil is formed and then the portion corresponding to the one non-circular coil is cut from the wire M. Be different. Further, when the non-circular coil manufacturing device according to the present embodiment cuts the part corresponding to one non-circular coil from the wire M, at least one of the two lead parts of the non-circular coil is the base end part of the lead part. The second embodiment is different from the first embodiment in that it has a function of bending.

As shown in FIG. 12, the non-circular coil manufacturing device according to the present exemplary embodiment is in a state where the wire rod conveying unit 2, the wire rod holding unit 2004, and the non-circular winding portion MC200 are formed at the tip of the wire rod M. , A cutting unit 2006 for cutting one non-circular coil from the wire M. Note that, in FIG. 12, the same components as those in Embodiment 1 are denoted by the same reference numerals as those in FIG. In addition, this non-circular coil manufacturing device, similar to the non-circular coil manufacturing device described in the first embodiment, has a winding unit (not shown), a forming unit (not shown), and a heating unit (not shown). No.), a transfer unit (not shown) that transfers the molding unit in the X-axis direction, and a transfer unit (not shown) that transfers the heating unit in the X-axis direction. Furthermore, the non-circular coil manufacturing device according to the present embodiment also includes a transport unit (not shown) that transports the cutting unit 2006 in the Y-axis direction.

The wire rod holding unit 2004 holds the portion of the wire rod M in which the non-circular winding portion MC200 is formed, excluding the circular winding portion MC200, and the portion of the wire rod M excluding the non-circular winding portion MC200, from the cutting unit 2006. It is arranged apart from the cutting unit 2006 in the stretching direction, that is, the Y-axis direction. The wire rod holding unit 2004 includes a lower tool 2041, an upper tool 2042, a tool driving unit 2044 that drives the lower tool 2041, and a tool driving unit 2045 that drives the upper tool 2042. On the +Z direction side of the lower tool 2041, as shown in FIG. 13A, a protrusion 2041a that protrudes toward the +Z direction side is provided. Further, on the −Z direction side of the upper tool 2042, a concave portion 2042a into which the protruding portion 2041a is fitted is provided. The wire M, which is the base of the non-circular coil to be manufactured, is sandwiched between the bottom of the recess 2042a of the upper tool 2042 and the tip surface of the protrusion 2041a of the lower tool 2041. Further, on the +Y direction side of each of the lower tool 2041 and the upper tool 2042, grooves 2041b and 2042b extending in the Z-axis direction are formed.

As shown in FIG. 13B, the cutting unit 2006 includes a base tool 2061, a wire rod holding tool 2062 arranged on the +Z direction side of the base tool 2061, and a bending arranged on the −Z direction side of the base tool 2061. And a cutting tool 2063. The non-circular winding part MC200 of the wire M is placed on the base tool 2061. The cutting unit 2006 also includes a tool driving unit (not shown) that drives the wire rod holding tool 2062 in the Z-axis direction with respect to the base tool 2061. Further, the cutting unit 2006 has an arm driving unit (not shown) that drives the two arms 2631A and 2631B of the bending cutting tool 2063 separately in the Z-axis direction with respect to the base tool 2061.

The base tool 2061 includes a long tool body 2611 and four columnar guide portions 2612 projecting from both ends in the short-side direction at two locations in the longitudinal direction of the tool body 2611. Further, a projection 2611a is provided at the tip of the tool body 2611. The wire rod holding tool 2062 holds the non-circular winding portion MC200 of the wire rod M placed on the base tool 2061 from one direction orthogonal to the extending direction of the wire rod M, that is, the +Z direction. The wire rod holding tool 2062 has a flat plate-shaped tool body 2621 and a wire rod holding portion 2622 extending from the tool body 2621 toward the −Y direction side. As shown in FIG. 12, a concave portion 2622a into which the non-circular winding portion MC200 formed at the tip of the wire M is fitted is formed on the −Z direction side of the wire rod pressing portion 2622. Further, as shown in FIG. 13B, the tool main body 2621 is formed with two through holes 2621a penetrating in the thickness direction and extending in the X-axis direction. Then, as shown in FIG. 12, the tool main body 2621 is arranged on the +Z direction side of the base tool 2061 in a state where the +Z direction side end of the guide portion 2612 is inserted into each of the two through holes 2621a. Further, the wire rod holding tool 2062 is parallel to the winding axis of the non-circular winding portion MC200 in the state where the wire rod holding unit 2004 holds the wire rod M and holds the non-circular winding portion MC200 of the wire rod M. It has a first surface 2622b facing the holding unit 2004.

As shown in FIG. 13B, the bending cutting tool 2063 includes two elongated arms 2631A and 2631B and a bite portion 2632 protruding from the −Y direction side end portions of the arms 2631A and 2631B toward the +Z direction side. And have. The cutting tool 2632 is plate-shaped and has a blade 2632a at its tip. Further, two cutout portions 2631a are formed in each of the two arms 2631A and 2631B. As shown in FIG. 12, the arms 2631A and 2631B have the −Z direction side of the base tool 2061 with the −Z direction side end of the guide portion 2612 inserted inside each of the two notches 2631a. Is located in. The bending and cutting tool 2063 moves the bite part 2632 in the +Z direction after pressing by cutting the bite part 2632 from the other direction orthogonal to the extending direction of the wire M to the cut portion MCa of the wire M, that is, the −Z direction. By doing so, the lead portion 2101 of the non-circular coil 2100 is bent. Here, in the cutting unit 2006, after the non-circular coil 2100 is separated from the wire M, the second surface 2632b of the bite part 2632 on the side opposite to the wire holding unit 2004 side becomes the first surface 2622b of the wire holding tool 2062. The bite portion 2632 is moved in the +Z direction so that the lead portion 2101 is sandwiched between the first surface 2622b and the second surface 2632b so as to be parallel. In addition, the tool driving unit that drives the bending cutting tool 2063 supports the two arms 2631A and 2631B at their base ends, and drives the two arms 2631A and 2631B separately in the Z-axis direction. At this time, the arms 2631A and 2631B move in the Z-axis direction while being guided by the guide portion 2612 of the base tool 2061.

Next, the operation of the non-circular coil manufacturing device according to this embodiment will be described. First, similarly to Embodiment 1, the circular winding portion MC201 is formed at the tip of the wire M. Next, as shown by arrows AR201 and AR202 in FIG. 14, in the wire rod holding unit 2004, the tool driving units 2044 and 2045 drive the lower tool 2041 and the upper tool 2042, respectively, in the directions toward each other, so that the wire rod M Are clamped by the lower tool 2041 and the upper tool 2042. Then, as shown by arrow AR203, the holding portion 23 is moved in the −Y direction. At this time, in the support base driving unit 25 shown in FIG. 12, the holding unit 23 causes the distance L1 corresponding to the length required for producing one non-circular coil 2100 from the cutting portion Mc that cuts the circular coil C1 from the wire M. The support base 24 is moved to a standby position (second position) Pos0 capable of holding the holding target portion Mb spaced apart by only.

Then, similarly to Embodiment 1, the forming tool 51 of the forming unit 5 causes the circular winding portion MC201 of the wire M held by the wire rod holding unit 2004 to move from the −X direction side of the circular winding portion MC201 to the − of the circular winding portion MC201. Inserted on the Z side. Further, the punch 52 of the forming unit 5 is inserted from the −X direction side of the circular winding portion MC201 of the wire M held by the coil holding unit 4 to the +Z direction side of the circular winding portion MC201.

Next, the heating unit applies hot air to the circular winding portion MC201 to heat the circular winding portion MC201 and melt and fix the coating film forming the circular winding portion MC201. Subsequently, while heating the circular winding portion MC201 by the heating unit, as shown by an arrow AR204 in FIG. 15A, in the forming unit 5, the punch 52 is driven in the −Z direction to taper the portion 521 of the punch 52. Is brought close to the circular winding portion MC201. Then, the punch 52 is further driven in the −Z direction, and the punch 52 is caused to enter the inside of the circular winding portion MC201. At this time, the circular winding portion MC201 is deformed so as to extend in the X-axis direction and becomes a non-circular shape. Here, as the circular winding portion MC201 is deformed into a non-circular shape, the two support portions 511, 512 are moved so that the distance between the two support portions 511, 512 in the X-axis direction increases. Subsequently, as shown by an arrow AR205 in FIG. 15B, the punch 52 is moved in the +Z direction. In this way, the non-circular winding portion MC200 having a non-circular shape in plan view is formed at the tip of the wire M.

After that, as shown in FIG. 16, the cutting unit 2006 is arranged in the vicinity of the non-circular winding portion MC200 of the wire M. Next, the cutting unit 2006 is further moved in the −Y direction to fit the protrusion 2611a of the base tool 2061 into the groove 2041b of the lower tool 2041 of the wire rod holding unit 2004, as shown in FIG. By thus fitting the protrusion 2611a into the groove 2041b, the base tool 2061 is positioned with respect to the wire rod holding unit 2004.

Subsequently, by moving the wire rod holding tool 2062 in the −Z direction, the non-circular winding portion MC200 is fitted inside the recess 2622a of the wire rod holding portion 2622 as shown in FIG. 17B. Here, the distance GA1 between the first surface 2622b and the second surface 2632b when the second surface 2632b of the bite portion 2632 is arranged at a position facing the first surface 2622b is based on the thickness of the wire M. Is set. For example, the distance GA1 is set to be longer than the thickness of the wire M by a distance of 10 μm or less.

After that, as shown by an arrow AR206 in FIG. 18, the arm driving unit drives the arm 2631A (2631B) in the +Z direction. At this time, the wire M is cut at the tip of the bite portion 2632 of the bending cutting tool 2063, and as shown by an arrow AR207, the lead portion 2101 of the non-circular coil 2100 cut from the wire M is +Y of the bite portion 2632. It is bent to the +X direction side along the side surface on the direction side. Here, of the two lead parts 2101 of the non-circular coil 2100, the lead part 2101 located on the −X direction side is arranged on the +Z direction side compared to the lead part 2101 located on the +direction side. Then, the arm drive unit moves the arm 2631B to the +Z direction side as compared with the arm 2631B by an amount corresponding to the distance difference between the two lead units 2101 in the Z-axis direction.

Next, the bending cutting tool 2063 is moved to the −Z direction side, and the wire rod holding tool 2062 is moved to the +Z direction side. After that, the blower blows air to the non-circular coil 2100 placed on the base tool 2061 to blow the non-circular coil 2100 toward the product collecting unit.

The non-circular coil 2100 manufactured by these series of steps is, as shown in FIGS. 19A and 19B, a p-direction (fourth direction) orthogonal to the winding axis J2 of the non-circular winding portion 2102. Has a longer inner diameter W211 than the second inner diameter W212 in the q direction (fifth direction) orthogonal to the winding axis J2 and the p direction. Further, each of the non-circular winding portion 2102 and the lead portion 2101 has a width of 0.5 mm or less and a thickness of 55 μm or less. Furthermore, the first inner diameter W211 is set to 1.5 mm or less. Further, the lead portion 2101 is bent at the base end portion thereof in the direction along the winding axis J2 of the winding portion 2102, that is, in the +r direction (sixth direction) and extends in the +r direction. Examples of the non-circular coil 2100 include a coil having a first inner diameter W211 of 1.2 mm and a second inner diameter W212 of 0.7 mm. Further, the length W213 of the non-circular coil 2100 in the q-axis direction can be set to 0.7 mm or more and 1.0 mm or less. Further, the length W215 of the non-circular coil 2100 in the r-axis direction can be set to 1.2 mm or more and 1.5 mm or less. Further, the number of turns of the non-circular winding portion 2102 can be set to, for example, 6 to 7 turns, and in this case, the thickness W214 of the non-circular winding portion 2102 is set to 0.3 to 0.4 mm. You can Then, in the direction orthogonal to the winding axis J2 of the non-circular winding portion 2102 of the non-circular coil 2100, that is, in the q-axis direction, the edge of the non-circular winding portion 2102 on the side of the lead portion 2101 and the winding of the lead portion 2101. The distance W216 between the edge on the side of the turning portion 2102 is 0.2 mm or less.

As described above, according to the non-circular coil manufacturing device according to the present embodiment, the non-circular coil 2100 in which the lead portion 2101 is bent can be created in the cutting unit 2006. Therefore, variations in the shape of the non-circular coil 2100 can be increased.

Although the respective embodiments of the present invention have been described above, the present invention is not limited to the configurations of the respective embodiments described above. For example, as the wire M, one having a circular cross section, a triangle, or another shape may be adopted.

In the transport units 7 and 8 according to the first embodiment, the configuration including the coil springs 72 and 82 has been described, but the configuration is not limited to the configuration including the coil spring, and may include, for example, an air spring or an elastic member. It may be. Further, in the embodiment, the transport units 7, 8 have been described as having a transport mechanism using the coil springs 72, 82 and the cams 74, 84, but the type of the transport mechanism is not limited to this. Instead, for example, a transport mechanism using a slider and a ball screw may be provided.

In the first embodiment, an example in which the standby position of the molding unit 5 is located on the −X direction side of the winding unit 3 has been described, but the standby position of the molding unit 5 is not limited to this. For example, the standby position of the molding unit 5 may be located on the +Y direction side or the ±X direction side of the winding unit 3.

Although the respective embodiments and modifications of the present invention have been described above, the present invention is not limited to these. The present invention includes a combination of the embodiments and the modified examples as appropriate and a modification of which is appropriately added.

The present invention is suitable for manufacturing a non-circular coil used for a small device such as a mobile phone.

2: Wire material transport unit, 3: Winding unit, 4: Coil holding unit, 5: Molding unit, 6: Heating unit, 7, 8: Transport unit, 21: Tension applying section, 23: Holding section, 23a: Insertion hole , 24, 54: support base, 25: support base drive part, 31: stage, 32: core metal, 33: pedestal part, 33a: flat surface, 34: stage drive part, 35: core metal drive part, 41, 2041 : Lower tool, 42, 2042: Upper tool, 43: Cutter, 44: Cutter drive part, 45, 2044, 2045: Tool drive part, 51: Molding tool, 52: Punch, 53: Base part, 55: Support plate , 56: punch driving unit, 57: pressing member, 57a, 57b: abutting unit, 58: coil spring, 61: hot air blower, 62: nozzle, 72, 82, 2132A, 2132B: coil spring, 73, 83: fixed Member, 74, 84: Cam, 81: Slide body, 100, 2100, C2: Non-circular coil, 101, 2101: Lead part, 102, 2102, MC200: Non-circular winding part, 211: Holding claw, 212: Shaft Part, 213: pressing force adjusting part, 221, 222: guide roller, 311, 572, 2042a, 2131a: concave part, 331: claw part, 331a: tapered surface, 332: inclined part, 511, 512: support part, 511a: 1st groove, 512a: 2nd groove, 511b: 1st mounting surface, 512b: 2nd mounting surface, 511c: 1st opposing surface, 512c: 2nd opposing surface, 521: taper part, 541: support part drive Part, 571: through hole, 2004: wire rod holding unit, 2006: cutting unit, 2041a: projecting portion, 2041b, 2042b: groove, 2061: base tool, 2062: wire rod holding tool, 2063: bending cutting tool, 2131: body portion 2131b and 2131c: screw holes, 2133A and 2133B: adjusting screws, 2611 and 6221: tool body, 2611a: protrusion, 2612: guide portion, 2621a: through hole, 2622: wire rod holding portion, 2622a: concave portion, 2622b: second 1 surface, 2631a: notch portion, 2631A, 2631B: arm, 2632: bite portion, 2632a: blade, 2632b: second surface, C1: circular coil, J0, J1: center axis, J2: winding axis, J11, J12. , J13: rotating shaft, M: wire rod, Ma: tip portion, Mb: holding target portion, Mc: cutting portion, MC201: circular winding portion, Pos0: standby position, Pos1: first position, W11, W211: first. Inner Diameter, W12, W212: Second Inner Diameter

Claims (13)

A winding unit that winds a wire rod in a circle to form a circular winding portion that is circular in plan view on the wire rod,
A molding unit for molding the circular winding portion into a non-circular winding portion having a non-circular shape in plan view,
The molding unit is
The cross-sectional shape that is rod-shaped and orthogonal to the central axis is a similar shape to the shape inside the non-circular winding portion, and the area of the cross-section orthogonal to the central axis is smaller toward the first direction side along the stretching direction, and at least the above A punch provided with a taper portion having a maximum width in a direction orthogonal to the central axis at an end portion on the first direction side, the taper portion being smaller than an inner diameter of the circular winding portion,
Two support portions that support the circular winding portion from the first direction side,
A punch driving unit that drives the punch in the first direction side and inserts the punch into the inside of the circular winding unit from the end portion in the first direction side;
As the circular winding portion is deformed so as to extend in the second direction orthogonal to the first direction, the two support portions are arranged so that the distance between the two support portions in the second direction expands. A supporting section driving section for driving,
Non-circular coil manufacturing equipment. The two support parts are
A first support part and a second support part arranged so as to face the first support part in the second direction,
The first supporting portion is orthogonal to the first mounting surface on which a part of the circular winding portion is mounted, and extends in the first direction from the first mounting surface side. An existing first groove is formed, and a first facing surface facing the second supporting portion is provided,
The second support portion is orthogonal to the second mounting surface on which a part of the circular winding portion is mounted, and extends from the second mounting surface side in the first direction. An existing second groove is formed, and a second facing surface facing the first supporting portion is provided,
In the third direction orthogonal to the first direction and the second direction, the position of the first groove and the position of the second groove are the same,
The first groove and the second groove are the inside of the first groove and the inside of the second groove in the second direction in a state where the first facing surface and the second facing surface are in contact with each other. The longest distance between them is formed to be equal to or less than the inner diameter of the circular winding portion,
The non-circular coil manufacturing device according to claim 1. The molding unit presses the circular winding portion from a side opposite to the two supporting portions in a state where the circular winding portion is supported by the two supporting portions, so Further comprising a pressing member for sandwiching the circular winding portion,
The non-circular coil manufacturing device according to claim 1 or 2. A wire rod carrying unit for carrying the wire rod supplied from the outside to the winding unit,
The wire rod transport unit,
In the wire rod supplied from the outside, a holding portion that holds a holding target portion that is separated from the tip end portion of the wire rod by a distance corresponding to a length required for producing one of the non-circular coils,
A guide roller for guiding the wire rod to the holding portion,
A tension applying section for applying tension to the wire,
A support base that collectively supports the holding portion, the guide roller, and the tension applying portion,
A support base drive unit that drives the support base along the extending direction of the wire rod,
The support base drive unit,
When forming the circular winding portion by the winding unit, the circular winding portion of the wire rod is held in a state where the wire rod is held by the holding portion and tension is applied to the wire rod by the tension applying portion. Moving the support to a first position where a portion corresponding to the circular coil has is located in the winding unit,
When one said circular winding part is produced|generated by the said winding unit, the said holding|maintenance part is required for manufacture of the one said non-circular coil which has the said non-circular winding part from the cutting site|part which cuts the said wire. Moving the holding target part separated by a distance corresponding to the length to a second position where it can be held,
The non-circular coil manufacturing device according to any one of claims 1 to 3. The tension applying section,
A pressing claw, the base end of which is axially supported by a shaft fixed to the support base and the tip of which abuts the wire and presses the wire at the tip.
A first urging member that urges the pressing claw in a first rotation direction in which the tip end of the pressing claw is pressed against the wire with the base end as a fulcrum;
A second urging member that urges the pressing claw in a second rotation direction opposite to the first rotation direction in which the tip end of the pressing claw is separated from the wire with the base end as a fulcrum.
A first adjusting portion for adjusting a first urging force of the first urging member;
A second adjusting portion for adjusting a second urging force of the second urging member,
The non-circular coil manufacturing device according to claim 4. The wire rod has a core wire and a coating that covers the core wire,
Before the circular winding portion is deformed by the forming unit, further comprising a heating unit for melting and fixing the coating film forming the circular winding portion by heating the circular winding portion,
The non-circular coil manufacturing device according to any one of claims 1 to 5. A cutting unit for cutting one non-circular coil from the wire rod in a state where the non-circular winding portion is formed at the tip of the wire rod;
In the state in which the non-circular winding portion of the wire rod in which the non-circular winding portion is formed is held, the cutting is performed in the extending direction of the portion of the wire rod excluding the non-circular winding portion from the cutting unit. Further comprising a wire rod holding unit arranged apart from the unit,
The cutting unit is
A base tool on which the non-circular winding part is placed,
A wire rod holding tool for holding the non-circular winding portion placed on the base tool from one direction orthogonal to the extending direction of the wire rod,
It has a bite part that is plate-shaped and has a blade at its tip, and in a state where the wire rod is held by the wire rod holding unit and the wire rod holding tool, it is orthogonal to the extending direction of the wire rod at the cutting portion of the wire rod. After cutting by pressing the bite part from the other direction to do, a bending cutting tool for bending the lead part of the non-circular coil cut from the wire rod by moving the bite part in the one direction, and
The non-circular coil manufacturing device according to any one of claims 1 to 6. The wire rod holding tool is parallel to the winding axis of the non-circular winding portion and faces the wire rod holding unit in a state where the wire rod holding unit holds the wire rod and holds the non-circular winding portion. Has a first surface to
In the cutting unit, after the non-circular coil is separated from the wire rod, a second surface of the bite portion opposite to the wire rod holding unit side in the thickness direction of the bite portion is parallel to the first surface. And moving the bite portion in the one direction so as to sandwich the lead portion between the first surface and the second surface.
The non-circular coil manufacturing device according to claim 7. The distance between the first surface and the second surface when the bite portion is arranged at a position where the second surface faces the first surface is set based on the thickness of the wire rod. ing,
The non-circular coil manufacturing device according to claim 8. A step of winding a wire into a circle to form a circular winding part,
A rod-shaped cross-section orthogonal to the central axis is similar to the shape inside the non-circular winding portion of the non-circular coil to be produced, and the cross section orthogonal to the central axis is closer to the first direction along the extending direction. A punch having a small area and a tapered portion having a maximum width at least at the end portion on the first direction side in the direction orthogonal to the central axis is smaller than the inner diameter of the circular winding portion, Is inserted into the inside of the circular winding portion from the end of the circular winding portion, and the circular winding portion is deformed so as to extend in the second direction orthogonal to the first direction. Forming the circular winding portion into the non-circular winding portion by moving the two supporting portions so that the distance between the two supporting portions supporting from the first direction side in the second direction is widened. And including,
Non-circular coil manufacturing method. While holding the wire rod in which the circular winding portion is formed, from a direction orthogonal to the extending direction of the wire rod at a cutting site in the wire rod, a bite portion having a blade at the tip end is plate-shaped. After pressing and cutting, the method further includes the step of bending the lead portion of the non-circular coil by moving the bite portion in the other direction opposite to the one direction.
The method for manufacturing a non-circular coil according to claim 10. A winding part that has a rectangular cross section and is wound in a non-circular shape,
Two lead portions each having a rectangular cross section and extending from both end portions in the extending direction of the winding portion,
A first inner diameter in a fourth direction orthogonal to the winding axis of the winding portion is longer than a second inner diameter in a fifth direction orthogonal to the winding axis and the fourth direction,
The winding portion and the lead portion each have a width of 0.5 mm or less and a thickness of 55 μm or less,
The first inner diameter is 1.5 mm or less,
Non-circular coil. The lead portion extends at a base end portion of the lead portion in a sixth direction along a winding axis of the winding portion, and the lead in the winding portion extends in a direction orthogonal to the winding axis. The distance between the edge on the part side and the edge on the winding part side in the lead part is 0.2 mm or less.
The non-circular coil according to claim 12.