JP5191846B2 - Circular multi-stage coil and winding method thereof - Google Patents

Description

  The present invention relates to a circular multi-stage coil (including a rectangular multi-stage coil having a short straight line portion) for winding and laminating a flat rectangular electric wire, and a winding method for forming a flat electric wire and winding it on the circular multi-stage coil.

  Conventionally, in order to efficiently manufacture a multi-stage coil, after using a motor power to roll a rectangular electric wire in a plate thickness direction with a pair of rolling rollers, it is wound concentrically to form an annular coil. Has been done. For the pair of rolling rollers, a technique has been proposed in which the pressing angle in the plate thickness direction of the flat electric wire is varied in accordance with the radius of curvature of the curved portion of the coil (see Patent Document 1).

  The present invention relates to an annular coil used in a transformer or the like, and in particular, as a technique for forming a curved portion such as a corner portion of a coil by deforming a cross-sectional shape of a conductor strand, a coil strand that forms a curved portion of the annular coil. For the portion, the coil wire is rolled by the first roller with the deformation amount of the portion closer to the outer peripheral side than the portion closer to the inner peripheral side of the annular coil within the cross section being rolled and bent in the length direction. After the deformation, it has been proposed to further bend and deform the wire portion having the cross-sectional deformation in the length direction by a second roller (Patent Document 2). Even in a curved part (curved part) with a small radius of curvature such as a corner part of an annular coil or a large amount of rolling deformation in the plate thickness direction by a rolling roller, the insulation coating is not broken or the conductor space factor is not lowered. Thus, it is possible to reduce the loss and the like while eliminating the breakdown of the insulating coating.

  FIG. 5 is a bird's eye view showing a coil in which a flat wire is wound around a disk and laminated in multiple stages. In order to wind the flat electric wire 1, the forming of the flat electric wire 1 is changed by an amount corresponding to the electric wire width while it is wound once, and the forming operation is repeated from the outer periphery to the inner periphery. By this reverse molding operation, the wire is wound from the inner periphery to the outer periphery. A multi-stage coil is manufactured by stacking a predetermined number of stages. In order to laminate the rectangular electric wire 1 of this coil, it is necessary to wind and laminate the formed rectangular electric wire 1 while aligning without deviation.

  FIG. 6 is an overall schematic diagram illustrating an example of a winding device for a multistage coil for a transformer, where (a) is a plan view and (b) is a front view. As shown in FIG. 6, in the winding device, the flat electric wire 1 wound around the electric wire drum 1 a is fed out from the electric wire drum 1 a and supplied to the flat electric wire forming unit 2. The flat wire forming part 2 can be adjusted in position within the plane and can be moved up and down by a mechanism such as a screw mechanism in accordance with the lamination of the coils. The supply unit of the flat electric wire 1 includes a feeding device and various guide rollers. The flat electric wire 1 is sent to the forming part 2 while being fed by a predetermined amount by a feeding device. The formed flat electric wire 3 is laminated while being wound by a disk in the flat electric wire lamination part 4 to produce a multistage coil.

  FIG. 7 is a perspective view illustrating the flat wire forming part 2 of the winding device shown in FIG. 6 in detail and explaining the principle of flat wire forming. As shown in FIG. 7, the molding unit 2 sandwiches the rectangular electric wire 1 in the thickness direction and the width guide rollers 7 and 7 for guiding the feeding before the molding, and the rectangular electric wire 1 guided in the feeding in the thickness direction. Rolling rollers 8 and 8, and forming rollers 9 and 9 for forming the flat electric wire 1 again in the width direction. Although not shown, a group of guide rollers for guiding the delivery of the flat electric wire 1 after molding can be provided.

  The rolling rollers 8 and 8 perform rolling processing on the curved portion of the disk winding, and perform curving by rolling more strongly and extending toward the outer side in the radius direction of curvature of the curved portion. Therefore, the width guide rollers 7 and 7 make the position guide in the width direction accurate. In this example, since the flat electric wire lamination | stacking part 4 is wound up as a circular coil, the flat electric wire 1 sent linearly is always roll-formed with the rolling rollers 8 and 8, and is formed into the curved electric wire. The group of guide rollers guides the bent electric wires in a disk-like manner to the flat electric wire laminating portion 4 and stacks them.

  8 and 9 are bird's-eye views showing examples of a rectangular multi-stage coil and a circular multi-stage coil manufactured by such an apparatus, respectively. In the rectangular multistage coil shown in FIG. 8, the rectangular electric wire 1 is formed by repeating the corner portion 6 and the straight portion 5, and the formation of the rectangular electric wire 1 is changed at a limited side or a limited corner portion. It is wound and further laminated.

  10 and 11 are diagrams for explaining how to wind the rectangular multistage coil. As shown in FIGS. 10 and 11, in the above-described conventional winding method, the disk wound from the outside to the inside shown in FIGS. 10 (a) and 11 (a), and FIG. 10 (b) and FIG. A rectangular multi-stage coil shown in FIGS. 10 (c) and 11 (c) is manufactured by superimposing the coils wound from the inside to the outside shown in FIG. 11 (b). Both the upper and lower disks are produced. , There are corner portions 6a and straight portions 5a that do not change, and the rectangular electric wires 1 formed at these portions can be aligned and aligned to complete a rectangular multistage coil. However, other than that, there is a portion where the overlap is shifted vertically or substantially not overlapped.

  FIG. 12 is a view for explaining how to wind a circular multistage coil as shown in FIG. As shown in FIG. 12, in the case of a circular multistage coil, the following manufacturing method is common. That is, as shown in FIG. 12 (a), the R wire is gradually reduced from the outer periphery so that the flat wire 1 becomes inside the flat wire 1 which has been previously arc-formed while being wound once. To do. This operation is performed for a predetermined number of rows, and then the rectangular electric wire 1 is formed into an arc from the inside to the outside as shown in FIG. The operations shown in FIGS. 12A and 12B are repeated to wind the disk (FIG. 12C), and stack them. The method shown in FIG. 12 is also applied to the case where a rectangular multistage coil having a short straight portion 5a is manufactured.

However, in this method, the arc forming of the flat electric wire 1 is gradually changed, and the flat electric wire 1 is changed from the outside to the inside or from the inside to the outside for each step. It is. Further, when a circumferential shift (twist) occurs while the flat wire 1 is laminated from the arc-formed portion, the matching portion is not known, and alignment and lamination become difficult. Thus, mass production is impossible in the case of a circular multistage coil or a rectangular multistage coil with a short straight line portion.
Japanese Patent No. 3996005 JP 2006-196682 A

  Therefore, there is a need for a winding method for easily aligning and stacking rectangular electric wires for each stage without reducing the space factor in a circular multistage coil (including a rectangular multistage coil with a short straight line portion) and its winding method. Therefore, an object of the present invention is to provide a circular multi-stage coil and a winding method therefor that make it possible to easily align the flat electric wires for each stage without reducing the space factor.

The circular multi-stage coil according to the present invention is a circular multi-stage coil formed by winding a rectangular electric wire from the outer periphery to the inner periphery and then changing the radial direction from the inner periphery to the outer periphery in the radial direction by the line width , and repeatedly stacking the disk in plural stages. in the coil, the rectangular electric wire is disk winding, viewed in the circumferential direction of the disk, is divided into an angular range that does not change the arc shape and the line angle range width of only changing the arc shape, each It is characterized in that the angle ranges in which the arc shape of the disk is not changed and the angle ranges in which the arc shape is changed are aligned and stacked on each other.

  In addition, the winding method of the circular multi-stage coil according to the present invention is the same as the winding of a circular multi-stage coil or a rectangular multi-stage coil with a short straight portion, and the rectangular electric wire between the outer periphery and the inner periphery, or from the inner periphery to the outer periphery. When the wire is wound by changing the width of the wire, the portion where the arc forming of the flat wire is changed is limited to one place or several places, and the flat wire is wound.

  According to the circular multi-stage coil and the winding method thereof according to the present invention, by limiting the portion that changes the arc forming, that is, the portion that changes the radius of curvature of the arc formation, the rectangular electric wire is moved from the outside to the inside for each step. Alternatively, an arc-shaped portion (range) that is different from the inside to the outside and an arc-shaped portion (range) that is the same in all stages are generated. The parts (ranges) having the same arc shape in all the stages have the same radius of curvature, that is, the same shape. Can be aligned and aligned. In addition, it has been difficult to align the arc-shaped portions from the outside to the inside or from the inside to the outside. However, by aligning the same arc-shaped portions, different arc shapes are formed. Therefore, it is possible to lay flat wires easily. The coil winding method according to the present invention can be applied not only to a case where the winding state is a circular multi-stage coil, but also to a rectangular multi-stage coil having a short straight portion. Hereinafter, the term “circular multi-stage coil” includes “a rectangular multi-stage coil having a short straight line portion”.

  The circular multi-stage coil and the winding method thereof according to the present invention make it easy to align and laminate flat-shaped electric wires formed in a circular arc shape in the winding of the circular multi-stage coil, thereby enabling mass production and production. . Furthermore, in the circular multistage coil and the winding method thereof according to the present invention, compared with the case where the arc shape is gradually changed, the overlapping portion between the upper and lower disks is increased, and the space factor of the rectangular electric wire is improved. Material cost reduction and coil characteristic improvement can be achieved.

  Embodiments of a circular multistage coil and a winding method thereof according to the present invention will be described below with reference to the drawings. As the winding device, one equivalent to that shown in FIGS. 6 and 9 can be adopted, and the description thereof is omitted here.

  As an embodiment, a circular multi-stage coil in which a portion where the arc shape of the flat electric wire 1 is changed as shown in FIG. The coil shown in FIG. 1 (c) is a coil in which the flat electric wire 1 is wound in a disk shape composed of two portions of the same arc portion 10c and the arc portion 11c to be changed and laminated.

  First, as shown in FIG. 1 (a), the flat electric wire 1 is formed into a disk shape with gaps in the radial direction sequentially filled from the outside to the inside. In other words, the flat electric wire 1 is formed in a range 10a limited to the same circular arc shape (having the same radius of curvature) at the outermost periphery. In this example, the range 10a is an angle range of 270 degrees corresponding to three quarters of the whole. In the next range 11a, the flat electric wire 1 is formed into an arc so as to be inside the line width from the outermost arc. The range 11a is an angle range of 90 degrees corresponding to the remaining quarter in this example. In the range 11a, from the start point to the end point of the limited range, the arc of the flat electric wire 1 may be formed so as to be inside the already wound flat electric wire 1. The radius of curvature of the arc is the same as the radius of curvature in the range 10a at the start point, but is shortened by the width of the flat wire 1 at the end point. By repeating this operation for a predetermined number of rows, the rectangular electric wire 1 is wound into a disk.

  Thereafter, as shown in FIG. 1 (b), the reverse operation sequentially fills the gaps in the radial direction from the inside to the outside, and the range 10b has the same arc shape (having the same curvature radius), and the next range 11b An arc is formed so that the flat electric wire 1 is inside the line width from the outermost arc. By repeating this process, the flat electric wire 1 is wound into a disk and formed into a disk shape, and the multi-layer coil is completed by aligning the same arc-shaped portions in the ranges 10a and 10b at all stages. To do.

  As described above, instead of gradually changing the arc forming of the flat electric wire 1 during one turn and finally changing the width of the electric wire, in the present invention, the arc forming is performed for each stage. By limiting the parts to be changed (ranges 11a and 11b), the flat wire is the same in all stages as the parts (ranges 11a and 11b) in which the electric wire changes from the outside to the inside or from the inside to the outside in an arc shape. Arc-shaped portions (ranges 10a and 10b) are generated, and among these, the same arc-shaped portions (ranges 10a and 10b) are exactly overlapped between the upper and lower disks, and are easily It is possible to align and align the flat electric wires 1 to each other. By aligning the same arc-shaped portions (ranges 10a and 10b) with respect to the portions that have been difficult to align in the past and are changing to different arc shapes from the outside to the inside or from the inside to the outside. As a result, the rectangular electric wires 1 can be easily laminated.

  According to the present invention, in the winding of a circular multi-stage coil, the flat electric wires 1 formed into an arc shape can be easily aligned and laminated, and mass production is possible. Furthermore, in the method of gradually changing the arc shape of the flat electric wire 1 shown in FIG. 12, a circular multi-stage coil is assumed assuming four rows, but if the row 12b of a part of the coil is made into four rows, The column 12a becomes 5 columns. However, in the winding method of the present invention (FIG. 1 (c)), both the rows 13a and 13b are four rows, and the space factor of the flat wire 1 is improved, leading to a reduction in material cost and an improvement in coil characteristics.

  FIG. 2 shows another embodiment of another circular multi-stage coil (and its winding method) according to the present invention. In the embodiment shown in FIG. 2, the range 14a, 14b, and 14c are connected by a straight line between the start point and end point of the range 11a (FIG. 2 (c)). In this embodiment, the overall shape of the coil is D-shaped, and accordingly, the space factor of the flat wire 1 is poor, and the coil characteristics can be deteriorated. However, it can be realized if there is no particular problem in actual characteristics. In this embodiment, the flat electric wire 1 is repeated in the form of an arc, a straight line, an arc, a straight line, and is not suitable for automatic continuous forming.

  FIG. 3 shows still another embodiment of another circular multi-stage coil (and its winding method) according to the present invention. In the embodiment shown in FIG. 3, the range 15a, 15b, and 15c are connected by a polygonal straight line between the start point and end point of the range 11a (FIG. 3C). In this embodiment, the overall shape of the coil is closer to a circle than in Embodiment 2, the space factor of the flat wire 1 is improved, and the characteristics of the coil are improved. However, as in Example 2, the flat electric wire 1 is repeated in the form of an arc, a straight line, a straight line, an arc, a straight line, a straight line, and is not suitable for automatic continuous forming.

FIG. 4 shows still another embodiment of another circular multi-stage coil (and its winding method) according to the present invention. In the embodiment shown in FIG. 4, the start point and end point of the range 11a are a range connected by multi-divided arcs. When the disk is wound from the outside to the inside, this range is a two-part arc of the range 11a-1 and the range 11a-2. When the disk is wound from the inside to the outside, the range 11b- 1 and a range 11b-2 are divided into two arcs. In this embodiment, the coil shape is also substantially circular, and a circular multistage coil can be manufactured without reducing the space factor. Furthermore, a coil shape with a better space factor can be obtained by drawing a trajectory that connects the multiple arcs by tangent lines. Further, the flat electric wire 1 is repeated in the form of an arc, an arc, an arc, and the automatic continuous molding is possible.
The calculation formula when the range 11a is divided into two and the arc is connected by a contact point is shown below. Here, R ₁ and R ₂ are respective radii before and after the connection of the divided arcs, R is a reference radius as shown from the coil center (origin position in the figure) with respect to the arc R ₁ , and A is a flat electric wire The wire width. Further, y is a distance from the coil center (origin position in the figure) to the arc center determined by the radii R ₁ and R ₂ . 4 (a) and 4 (b), (1) to (3) and (11) to (13) are established, and from these equations, the radii R ₁ and R ₂ and the distance y are obtained as follows: As shown in (5) to (7) and (15) to (17), respectively, it can be expressed by a reference radius R and a wire width A.
In the case of FIG.
On the 45 ° line R ₂ = R ₁ + y√2 (1)
On the 90 ° line -A + R = R ₂ -y (2)
On the 0 ° line, R = R ₁ + y (3)
If R ₂ is deleted from (1) and (2),
-A + R = R ₁ + y (√2-1) (4)
If y is deleted from (3) and (4),
(2-√2) R = A + (2-√2) R ₁
Therefore, R ₁ = R− (2 + √2) × A / 2 (5)
R ₂ = R + (√2) × A / 2 (6)
y = R−R ₁ = (2 + √2) × A / 2 (7)
In the case of FIG.
On the line of 45 °, R ₂ = R ₁ + y√2 (11)
On the 90 ° line A + R = R ₁ + y (12)
On the 0 ° line R ₂ = R + y (13)
If R ₂ is deleted from (1) and (3),
y = (√2 + 1) (R−R ₁ ) (14)
If y is deleted from (2) and (4),
A + R = R ₁ + (√2 + 1) (R−R ₁ )
Therefore, R ₁ = R− (√2) × A / 2 (15)
R ₂ = R + (2 + √2) × A / 2 (16)
y = A + R−R ₁ = (2 + √2) × A / 2 (17)

  There is a method in which the arc between the start point and end point of the range 11a is gradually changed and connected. Even in this embodiment, the overall shape of the coil is substantially circular, and a circular multistage coil can be manufactured without reducing the space factor. Moreover, since the flat electric wire 1 is an arc, automatic continuous molding is possible.

  The present invention makes it possible to improve the productivity and mass production by facilitating the lamination of a rectangular electric wire formed into an arc shape in a winding of a circular multi-stage coil or a rectangular multi-stage coil having a short straight portion of a molded transformer. . Further, the present invention relates to a winding method of a circular multistage coil or a rectangular multistage coil having a short straight line portion, which improves the space factor of a rectangular electric wire and reduces material cost and coil characteristics.

The top view when changing a circular arc in the limited part of a circular multistage coil. The top view when the limited part of a circular multistage coil is changed in a straight line. The top view when the limited part of a circular multistage coil is changed by the linear polygon. Arc calculation formula when changing the arc in a limited part of a circular multistage coil. A bird's-eye view of a circular multistage coil. The principle figure of multi-stage coil electric wire processing. The bird's-eye view of a rectangular multistage coil. A bird's-eye view of a circular multistage coil. The principle diagram of flat wire forming. The top view of how to wind a rectangular multistage coil. The top view of how to wind a rectangular multistage coil. The top view when changing a circular arc in the perimeter of a circular multistage coil.

Explanation of symbols

1: flat electric wire 2: flat electric wire forming part 3: formed flat electric wire 4: flat electric wire laminated part 5: straight part 5a: straight part (plan view)
6: Corner part 6a: Corner part (plan view)
7: Width guide roller 8: Rolling roller 9: Forming roller 10a: Same arc shape part (outer side → inner side)
10b: Same arc shape part (inside → outside)
10c: Same arc shape part (outer side → inner side, inner side → outer side)
11a: A part to change the arc (outside to inside)
11a-1: Arc 1 to be changed (outside to inside)
11a-2: Arc 2 to be changed (outside to inside)
11b: A part to change the arc (inside to outside)
11b-1: Arc 1 to be changed (inside to outside)
11b-2: Arc 2 to be changed (inside to outside)
11c: A part to change the arc (outside → inside, inside → outside)
12a: Number of rows of flat electric wires 12b: Number of rows of flat electric wires 13a: Number of rows of flat electric wires 13b: Number of rows of flat electric wires 14a: Change of flat electric wires in a straight line (outside to inside)
14b: Straight wire is changed in a straight line (inside to outside)
14c: Straight wire is changed in a straight line (inside → outside, outside → inside)
15a: Change the rectangular electric wire into a polygon (outside → inside)
15b: The rectangular electric wire is changed to a polygon (inside to outside)
15c: Change the rectangular electric wire into a polygon (inside → outside, outside → inside)

Claims (10)

In a winding method of a circular multi-stage coil in which a rectangular electric wire is wound around a disk by changing the radial direction by the line width from the outer periphery to the inner periphery, and then from the inner periphery to the outer periphery, and this disk is repeatedly stacked .
It said rectangular electric wire is disk winding, viewed in the circumferential direction of the disk, divided into a range of angles varying arc shape and an angle range that does not change the arc shape only the line width of,
Winding method of a circular multi-stage coil, characterized in that consists of aligning the angular range between of varying the arc shape do not change the angle range between and the arc shape of each disc was stacked with each other. In the winding method of the circular multistage coil according to claim 1,
The method of winding a circular multistage coil, wherein the angle range of the flat electric wire in which the arc shape is changed is an arc shape in which the radius of curvature is gradually changed. In the winding method of the circular multistage coil according to claim 1,
The angular range of the arc shape is changed in the rectangular electric wire is winding method of a circular multi-stage coil, characterized by comprising a linear shape. In the winding method of the circular multistage coil according to claim 1,
The arcuate shape of the angular range is changed, the winding method of a circular multi-stage coil, characterized by comprising a polygonal line shape which is convex in the radially outer side of the rectangular electric wire. In the winding method of the circular multistage coil according to claim 1,
The angular range of the arc shape is changed in the rectangular electric wire is winding method of a circular multi-stage coil, characterized by comprising connecting a plurality of radii of curvature of the arc shape. In a circular multi-stage coil formed by winding a rectangular electric wire from the outer periphery to the inner periphery, then changing the radial direction by the line width from the inner periphery to the outer periphery, and repeating this to pile up the disk in a plurality of stages .
It said rectangular electric wire is disk winding, viewed in the circumferential direction of the disk, divided into a range of angles varying arc shape and an angle range that does not change the arc shape only the line width of,
A circular multi-stage coil comprising: an angular range in which the circular arc shape of each disk is not changed and an angular range in which the circular arc shape is changed are aligned and stacked on each other. The circular multistage coil according to claim 6,
The circular multi-stage coil according to claim 1, wherein an angle range in which the arc shape of the flat electric wire is changed is an arc shape in which a radius of curvature is gradually changed. The circular multistage coil according to claim 6,
The angular range of the arc shape is changed in the rectangular electric wire is circular multi-stage coil, characterized by comprising a linear shape. The circular multistage coil according to claim 6,
The circular multi-stage coil is characterized in that an angle range obtained by changing the arc shape of the flat electric wire is a polygonal line shape protruding outward in the radial direction. Oite circular multistage coil according to claim 6,
An angular range in which the arc shape of the flat electric wire is changed is formed by connecting arc shapes having a plurality of curvature radii.

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