JPS59130637A - Method and device for producing coil - Google Patents

Abstract

PURPOSE:To bend a continuous conductor having many kinds of curvature with high efficiency without using any die by supplying the conductor between three rolls which are alternately arranged, and positioning the central roll according to the curvature at which the conductor is bent. CONSTITUTION:A device 9 which positions a central roll 7 and stationary rolls 6, 8 are held in a supporting base 10, and a conductor 1 is fed from a supply direction 15 to the space between the three rolls. A table 11 on which a coiling die 4A is placed and fixed is driven by a rotating device 12 and devices 13, 14 for moving in x- and y-directions. The roll 7 is located in this stage at the prescribed position in the y-direction according to the curvature for bending and the conductor 1 is bent in a way as to attain max. bending moment at the contact point with the roll 7. The roll 7 is positioned in accordance with the fresh curvature at the point where the curvature changes and the working is repeated. A large-sized non-circular coil is thus produced with high efficiency without using any die.

Description

[Detailed Description of the Invention] [Field of Application of the Invention] The present invention relates to a method and apparatus for manufacturing a coil, and in particular, to manufacturing a non-circular coil, such as a large non-circular coil, by bending a conductor into various curvatures. The present invention relates to a method and an apparatus for doing so.

[Prior art]

When manufacturing a coil, take into account the springback after bending the conductor, bend it to a slightly larger curvature than the desired one (hereinafter simply referred to as overbending), and then bend it to the desired curvature after unloading. It needs to be processed.

A conventional method for bending a conductor will now be explained with reference to FIG.

FIG. 1 is a partially sectional front view showing an example of a conventional conductor bending apparatus and a conductor bent thereby.

In FIG. 1, a crescent-shaped mold 2 is inserted between a coil 3 that has already been wound on a coil winding mold 4 and a conductor 1 that is to be bent, and while applying a tensile force to the conductor 1, Wrap it around the crescent-shaped mold 2, overbend the length L of the conductor, then move the crescent-shaped mold 2 to the left,
The coil was manufactured by repeating the process of overbending the next unprocessed portion by length L.

However, the above-described coil manufacturing method has the following problems when applied to manufacturing a continuous conductor having various curvatures, such as a large non-circular coil.

Figure 2 shows an example of a continuous conductor with many types of curvature.
FIG. 3 is a front view showing a large non-circular coil.

In FIG. 2, reference numeral 5 denotes a large non-circular coil formed by continuously winding a conductor in a track shape from the inside to the outside.

In the conventional bending method described above, four types of crescent-shaped dies 2 similar to those shown in Fig. 1 are used for bending one turn of the track.
The rolled version required 40 different crescent-shaped molds, and the molds had to be replaced each time each part was processed.

Therefore, not only did mold costs become large, but mold replacement took a long time and work efficiency was low.

[Purpose of the invention]

The present invention eliminates the drawbacks of the prior art described above, and enables continuous conductors with various curvatures, such as large non-circular coils, to be
The object of the present invention is to provide a coil manufacturing method that allows highly efficient bending without using a mold, and a coil manufacturing apparatus that can be used directly for carrying out the method.

[Summary of the invention]

The structure of the coil manufacturing method according to the present invention is that in the method of manufacturing a non-circular coil by bending a conductor into various types of curvature, three coils are arranged alternately on both sides along the conductor supply direction.
A conductor is supplied between the main rollers, and the conductor is wound by rotating a table on which a coil winding die is placed and fixed.
By applying a bending force to the conductor using the central roller of the three rollers, a predetermined length range of the conductor is bent into a desired curved shape, and then at the point of change of curvature, A non-circular coil is manufactured by repeating the operation of positioning the center roller to a new position corresponding to the curvature to be bent and bending the next predetermined length range of the conductor. It is.

Further, the coil manufacturing apparatus according to the present invention has a configuration in which the central roller is movable and includes three rollers that can apply bending force to the conductor, and a positioning device that can position the central roller. The bending device includes a coil winding mold for winding the processed conductor, and a coil winding mold placed and fixed thereon, and during bending of the conductor, plastic deformation is generated in the already bent conductor. It also has a table that can be moved so as not to cause any disturbance.

[Embodiments of the invention]

Before entering into the description of the embodiments, the basic matters related to the present invention will be explained using FIG.

FIG. 3 is for explaining the basic matters related to the present invention.
FIG.

In FIG. 3, 1 is a conductor, and 6, 7, and 8 are three rollers consisting of an inlet roller, a central roller, and an outlet roller, which are arranged alternately on both sides along the conductor supply direction 15. The exit roller 8 is a rotatable roller that is fixed at a predetermined position, and the central roller 7 is a roller that is movable and rotatable in the X direction.These three rollers apply bending force to the conductor 1. (Details will be described later). 4A is a coil winding type for winding the already bent conductor. Note that the coordinate system is such that the conductor supply direction 15 is in the X direction, and the direction perpendicular thereto is in the X direction.

In this configuration, first, the central roller 7 is positioned at a predetermined position according to the curvature of the bending process of the conductor 1 (the relationship between the curvature of the bending process of the conductor 1 and the position of the central roller 7 in the X direction is , determined in advance by experiment).

When the conductor 1 is supplied between the three rollers from the supply direction 15 and a table (not shown) on which the coil winding mold 4A is mounted and fixed is rotated in the direction of arrow 16, the conductor 1 is supplied in the direction of arrow 17.
While being wound up in the direction, a bending force is applied such that the maximum bending moment is achieved at the contact point m with the central roller 7, and the material is bent into a predetermined curvature. After bending a predetermined length range of the conductor 1 with the above-mentioned curvature, at the point where the curvature changes, the central roller 7 is positioned at a new position corresponding to the curvature to be bent next, and the conductor 1 is bent at the next predetermined length. By repeating the bending process in the length range, a non-circular coil 3 is processed, and this is sequentially wound onto the coil winding die 4A.

The present invention will be explained below with reference to Examples.

FIG. 4 is a plan view showing an example of a coil manufacturing apparatus used for carrying out a coil manufacturing method according to an embodiment of the present invention, together with a conductor to be bent by the apparatus, and FIG. It is a side view seen from the direction of the figure.

In each figure, the same numbers as in FIG. 3 indicate the same parts. 9 is a positioning device capable of positioning the central roller 7; 10 is this positioning device 9. Entrance roller6. A support base 11 supporting the central roller 7 and the exit roller 8 has a coil winding mold 4 mounted thereon.
This table 11 is a table on which A is placed and fixed.
The table rotating device 12. X-direction moving device 13. The X-direction moving device 14 drives each one in the θ, x, and y directions (details will be described later).

A method of manufacturing a non-circular coil by bending the conductor 1 using the coil manufacturing apparatus configured as described above will be described.

First, the conductor 1 is passed between three rollers in the conductor supply direction 15, and its tip is fixed to the coil winding die 4A. The positioning device 9 moves the central roller 7 in the X direction and positions it at a predetermined position corresponding to a desired curvature.

Next, the table rotation device 12. X-direction moving device 13.
When the table 11 is driven by the X-direction moving device 14, a tensile force is applied to the conductor 1 as the table 11 rotates, and a bending force is applied such that the maximum bending moment occurs at the point of contact with the central roller 7. , non-circular coil 3
The coil winding die 4A sequentially winds the coil into the coil winding die 4A.

After bending a predetermined length range of the conductor J to a uniform curvature up to the point of curvature change, the central roller 7 is then bent in the X direction by the positioning device 9 in accordance with the curvature to be processed. The conductor 1 is moved and positioned at a new position, and a predetermined length range of the conductor 1 is bent into a uniform predetermined curvature in the same manner as described above.

By repeating the above operations, a non-circular coil 3-, λ can be manufactured without using a mold.

By the way, during the construction of the conductor 1, the bending force 11 was applied to the conductor 1, which was subjected to plastic deformation 7. 1) The method for driving the table 11 necessary for continuously winding the length range of the same curvature of the conductor into the winding die 4A of the coil 11 will be explained.

Figure 6 shows an example of a non-circular coil with 4 coils in one turn.
Top view showing a non-circular coil with different curvatures, seventh
The figure is a schematic diagram for explaining the movement of the table during bending of the first turn of the non-circular coil according to FIG. 6.

This non-circular coil is
The radius of curvature of the winding is R1 → R2 → R3 → R2 → R1 → R4
The movement of the table 11 when manufacturing this part will be explained using FIG. 7.

In FIG. 7, the same parts as those in FIG. 3 are denoted by the same numbers. And ■, ■, ■.

The curve passing through ■, ■, ■, and ■ is the path along which the coil center Q moves during bending. When the radius of curvature is R1, the coil center Q moves upwards from ■ to ■. When the radius of curvature is R2, the coil center Q moves upward. When processing a radius of curvature R3, the coil center Q is above ■～■; when processing a radius of curvature R2, the coil center Q is above ■～■; when processing a radius of curvature R1, the coil center Q is above ■～■. When processing the radius of curvature R4, the coil center Q is located above (1) and (2), respectively. u,, u2゜'3 +
04 are curvature radii R1, R2, respectively.

This is the distance between the centers of R3 and R4 and the center of the coil.

ψ1, ψ2. ψ3. ψ4 is the angle formed with the y-axis by a line segment connecting the point (2) or (2) with points on the y-axis whose distances from the origin are R+, R2, R3, and R4, respectively.

The position of the table 11 shown in FIG. 7 shows the coil center Q moving from point 2 to point 2. This corresponds to the case where the conductor 1 is bent to have a radius of curvature R1. The x and y coordinates of the coil center Q in this case are expressed as follows.

■→■ x=u1sin (ψ1+θ) + Y-RIu 1co
s (ψl+θ)・(υ Similarly, the movement of the coil center between each point is as follows.

■→■ x= u 2 sin (π+θ), y=R2-u,
, cos(πJugen-(2)■→■ x = u 3 sin G-ψ3+θL 3'=R3
−u3cos((p+θ)・(3)■→■ X=u2 sin (ψ2+θ), Y=R2−u2c
os(ψ2+θ)-(4)■→■ X=u1sin(rr+θ), y-R1-ulcos(
π+θ)...(5)■→■ x=u4sjn(-ψ4+θ) + Y-R4u4 c
os(-(6) of -ψ4+) Here, θ is the rotation angle of the coil center with the time when the coil center Q passes through each of the above points as 0.

Therefore, in bending the length range between each point, the coordinates (x, y) of the coil center Q should be adjusted to satisfy the above equations (1) to (6) with respect to the rotation angle θ of the coil center. ,
Table rotation device 12. X-direction moving device 13. If the table 11 is moved by the X-direction moving device 14, the tangent in the vicinity of the bending portion on the outer periphery of the coil (the origin in FIG. 7) can always be aligned with the y-axis. The same holds true for the second and subsequent rolls.

This makes it possible to continuously process the length range of the same curvature of the conductor 1 without causing plastic deformation to the conductor that has already been bent, and to wind it onto the coil winding die 4A. can.

According to the embodiment described above, when manufacturing non-circular coils 3 having various types of curvature, parts of the coil 3 having the same curvature can be processed continuously, so unlike the conventional method, the molding process is repeated several times. It is more efficient than those that perform bending while moving. Furthermore, the curvature of the bending process can be changed by moving the central roller 7 in the X direction.
There is no need to make a mold, and there is no need for mold production costs. Furthermore, there are effects such as eliminating the need for time-consuming work such as changing molds, making it possible to perform bending with high efficiency.

〔Effect of the invention〕

As explained in detail above, according to the present invention, a coil manufacturing method can bend a continuous conductor having various types of curvature, such as a large non-circular coil, with high efficiency without using a mold. and the equipment thereof.

[Brief explanation of drawings]

Fig. 1 is a partial cross-sectional front view showing an example of a conventional conductor bending device and a conductor bent by the device, and Fig. 2 is an example of a continuous conductor with various types of curvature. FIG. 3 is a front view showing a large non-circular filter, and FIG.
5 is a plan view showing an example of a coil manufacturing device used for carrying out a coil manufacturing method according to an embodiment of the present invention, and a conductor to be bent by the device; FIG.
6 is a plan view showing a non-circular coil having four types of curvature in one turn as an example of a non-circular coil; FIG. FIG. 3 is a schematic diagram illustrating the movement of the table during bending of the first turn of the non-circular coil according to the present invention. 1... Conductor, 3... Coil:, 4A... Coil winding type, 6... Entrance roller, 7... Center roller, 8...
...Exit roller, 9...Positioning device, 11...Table, 12...Table rotation device, 13...X direction movement device, 14...Y direction movement @ position ~ service 3 to mouth 4 4th Kuchi δ 5th Kuchiho Otsu Machiho 7 Evil talent ↑ 6 3 ・zu

Claims (1)

[Claims] 1. In a method of manufacturing a non-circular coil by bending a conductor into various types of curvature, the conductor is bent between three rollers alternately arranged on both sides along the conductive supply direction. A conductor is supplied, and a bending force is applied to the conductor by the central roller of the three rollers while the conductor is wound by rotation of a table on which a coil winding die is placed and fixed. After bending a predetermined length range of the conductor to a desired curvature, at the point where the curvature changes, the center roller is positioned at a new position corresponding to the curvature to be bent next, and the conductor is bent to the next predetermined position. A method for manufacturing a coil, characterized in that a non-circular coil is manufactured by repeatedly performing a bending process over a length range. 2. Three rollers whose central rollers are movable and capable of applying bending force to the conductor, a positioning device capable of positioning the central rollers, and a coil winding for winding the bent conductor. The coil winding die is placed and fixed thereon, and the coil winding die is placed and fixed thereon, and the coil winding die is moved during bending of the conductor so as not to cause plastic deformation to the already bent conductor. Characteristic coil manufacturing equipment.