Coil winding device and coil winding method

Abstract

To provide a coil winding device and a coil winding method for tightly winding a wire in a plurality of layers around a reel.SOLUTION: A reel 8 that rotates with respect to a base 1 by the driving force of a motor 5 winds a wire 3 supplied from a bobbin 2 via an inward warping device 9. The copper wire 3 formed by applying pressure from both sides of the copper wire 3 with a lower forming roller 10 and an upper forming roller 20 is bent in the circumferential direction into an upward convex shape in FIG. 1 by an outer wall surface 12 of the lower forming roller 10 at the inlet side where the wire is pressed, and is bent in the circumferential direction in a downward convex shape in FIG. 1 by the outer wall surface 22 of the upper forming roller 20 at the outlet side where the wire is pressed. As a result, the copper wire is bent in the opposite direction after being bent once, and is conveyed to the reel 8 as an inwardly warped copper wire 3 with a large bending resistance. Therefore, when the copper wire 3 is wound around the reel 8, it is possible to reliably suppress the expansion of the winding width of the winding as viewed from a rotation center axis 31 of the reel 8.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a winding device and a winding method that suppresses the expansion of a coil wound around a bobbin. [Background technology]

[0002] In the winding method of winding a wire around a winding object, it is necessary to keep the tension fluctuation within a specified range in order to align and wind the wire (copper wire) around a reel. However, if the shape of the reel around which the wire is wound or the moving speed of the winding fluctuates, the tension also fluctuates. In the conventional technology, a spring or the like is used to apply a constant load to the wire to control the tension, but when the tension fluctuates at high speed, this cannot keep up with the fluctuations. When the tension decreases, the copper wire sags, making it difficult to wind it in an orderly fashion around the reel.

[0003] Patent Document 1 discloses a technology in which, in a winding device, a wire bending device is disposed upstream of a winding form, the device comprising a first backup roller and a second backup roller rotatably supported on a machine frame at a fixed interval, and a reverse-camber roller that simultaneously clamps the wire between the first backup roller and the second backup roller, and applies plastic deformation to the wire by curving it in the opposite direction to the swelling direction of the wire that attempts to curve and bulge from the straight side of the winding form. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 3566753 Summary of the Invention [Problem to be solved by the invention]

[0005] Generally, the fixed core of a motor is made by winding wire in 3 to 4 layers around a rectangular winding frame with a high aspect ratio, and then assembling and arranging the multiple winding frames on an arc. At this time, since the gap between adjacent coils is narrow, it is necessary to reliably prevent the winding width of the wire wound around the winding frame from expanding. In a rectangular winding form with a high aspect ratio, bulging of the coil winding, especially on the long sides, makes it difficult to wind tightly. When the winding form rotates and winds the wire, for example, if the wire is wound in multiple layers on the short sides 82, 83 and long sides 84, 85 of the winding form 8 as shown in Figure 9, the coil winding, especially on the long sides 84, 85, tends to bulge. The present invention has been made in view of the above, and an object of the present invention is to provide a coil winding device and a coil winding method for tightly winding a wire around a bobbin in a plurality of layers. [Means for solving the problem]

[0006] The coil winding device of the present invention comprises: A base (1) and a reel (8) that is rotatably supported on the base and that winds the wire (3) supplied from a wire supply source (2); A drive source (5) that drives and rotates the reel; a first roller (10) that is rotatably supported on the base and that winds and shapes the wire at an inlet side of the reel; a second roller (20) that is rotatably supported on the base and that winds and shapes the wire at an inlet side closer to the reel than the first roller while applying a pinching pressure between the second roller and the first roller, a bending deformation is applied by an external force of the first roller, a pinching pressure is applied between the first roller and the second roller, and then a reverse bending deformation is applied in a direction opposite to the bending direction of the bending deformation by an external force of the second roller; A configuration is adopted in which the rotation central axes (11, 21) of the first roller and the second roller are disposed at positions eccentric by distances (d1, d2) so as to give an inward curvature to the wire being carried into the reel.

[0007] The central axis (11) of the rotation shaft of the first roller and the central axis (21) of the rotation shaft of the second roller are offset by a distance (d1) in the horizontal direction and a distance (d2) in the vertical direction. The values ​​of these distances (d1, d2) are not zero, but are set to a degree that causes inward bowing of the wire discharged from the second roller when it is wound around the reel.

[0008] In general, in coil winding devices, tension fluctuations vary depending on the shape of the reel. Tension also fluctuates depending on the movement speed of the wire wound around the reel. The degree of slack in the wire changes depending on the shape of the reel and the movement speed of the wire. According to the coil winding device of the present invention, by imparting a bending deformation in which the wire being wound around a rotating winding frame is bowed inward when viewed from the central axis of rotation of the winding frame, it is possible to suppress bulging of the winding width of the wire wound in layers around the winding frame.

[0009] The above-mentioned reverse bending deformation of the inward bow is performed by bending a wire that has already been bent in the opposite direction (reverse bending deformation), so that the inward bow deformation is easily maintained during the second reverse bending deformation, making it possible to wind the wire tightly around the reel. Generally, when a wire is wound around a reel that is rotating due to a driving force, the long side of a reel with a high aspect ratio (b / a in Figure 9) is prone to loosening, and if the wire is wound in a loose state, the winding width tends to expand.

[0010] However, with the coil winding device of the present invention, when wire is wound in multiple layers, for example three to four layers, around a rectangular winding frame with a high aspect ratio, the gap between the coils is small, making it possible to suppress bulging of the coil wound around the winding frame. Furthermore, according to the coil winding device of the present invention, when the tension of the wire being fed into the winding frame varies greatly, a relatively close and high density winding can be achieved in multiple layers. Furthermore, according to the coil winding device of the present invention, even if the moving speed of the wire being wound is increased, high-speed winding and aligned winding can be achieved with relatively suppressed expansion of the winding width.

[0011] When winding the wire around the spool, it is possible to reliably suppress any expansion of the wire (winding width) as viewed from the central axis of rotation of the spool. When a plurality of winding frames are assembled and arranged on a circular arc to manufacture the fixed core, it is possible to prevent the winding width of the plurality of layers of windings wound around adjacent winding frames from expanding. [Brief description of the drawings]

[0012] [Figure 1] 1 is a schematic front view of a coil winding device according to a first embodiment; [Diagram 2] 1 is a schematic diagram showing a relationship between a winding frame position and a wire position at different rotation angles of the winding frame in the first embodiment; FIG. [Diagram 3] FIG. 2 is a diagram showing a relationship between the rotational position of the reel, the rotational angle of the reel, and the moving speed of the wire in the first embodiment; [Figure 4] FIG. 1 is a schematic diagram showing a coil winding device according to a second embodiment; [Diagram 5] FIG. 13 is a partial schematic front view of a coil winding device according to a third embodiment; [Figure 6] 5A is a cross-sectional view taken along line VIA-VIA in FIG. 5; FIG. 5B is a schematic cross-sectional view of the wire after forming; [Figure 7] FIG. 11 is an explanatory diagram comparing a winding state of the third embodiment with a winding state without forming; [Figure 8] Schematic diagram of a comparative coil winding device; [Figure 9] FIG. 2 is a schematic perspective view illustrating the aspect ratio of a reel; [Figure 10] FIG. 2 is a schematic cross-sectional view showing a coil winding state on a winding frame; [Figure 11] FIG. 4 is a partial plan view of a fixed core to which a winding form on which a coil is wound is attached. [Figure 12] 3A and 3B are diagrams showing the roller surfaces of an upper forming roller and a lower forming roller according to the first embodiment. [Figure 13] 13A and 13B are diagrams showing modified examples of the roller surfaces of the upper forming roller and the lower forming roller. [Figure 14] 13A and 13B are diagrams showing modified examples of the roller surfaces of the upper forming roller and the lower forming roller. [Figure 15]13A and 13B are diagrams showing modified examples of the level of the central axis of rotation of the winding frame according to the fourth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, a winding tension control device according to an embodiment of the present invention will be described with reference to the drawings. Note that, in a plurality of embodiments, substantially the same components are given the same reference numerals, and the description thereof will be omitted.

[0014] First embodiment A first embodiment of the present invention will be described with reference to FIGS. In the first embodiment of the present invention, as shown in Figures 1 to 3, a copper wire 3 corresponding to a wire wound around a bobbin 2 corresponding to a wire supply source is tensioned by a tension control device 4 and then transported to an inward warping forming device 9.

[0015] The bow forming device 9 is provided between the tension control device 4 and the reel 8 on the transport path of the copper wire 3. In the bow forming device 9, the reel 8 receives a driving force from a motor 5 as a driving source and rotates in a rotation direction (counterclockwise in FIG. 1). The copper wire 3 supplied from the tension control device 4 is fed into the warp forming device 9 in a horizontal direction via a free roller 6 which guides the copper wire 3 in a predetermined direction.

[0016] The base 1 supports a lower forming roller 10, which corresponds to the first roller that bends and shapes the copper wire 3 fed in from both the top and bottom sides, and an upper forming roller 20, which corresponds to the second roller, via L-shaped brackets 13 and 23 so that they can rotate freely.

[0017] The rotation center axis 11 of the lower forming roller 10 is positioned horizontally eccentrically on the side of the rotation center axis 21 of the upper forming roller 20 that is a distance d1 away from the rotation center axis 31 of the reel 8, and is positioned vertically eccentrically on the side of the rotation center axis 21 of the upper forming roller 20 that is a distance d2 away. The outer wall surface 12 of the lower forming roller 10 is formed as a flat surface in the roller width direction, similar to the outer wall surface 22 of the upper forming roller 20. The copper wire 3 is clamped from both sides at the contact points between the outer wall surface 12 of the lower forming roller 10 and the outer wall surface 22 of the upper forming roller 20.

[0018] The copper wire 3 is shaped by applying pressure from both sides of the copper wire 3 with the lower forming roller 10 and the upper forming roller 20, and is bent in the circumferential direction into an upward convex shape in Fig. 1 by the outer wall surface 12 of the lower forming roller 10 on the inlet side where it is pressed, and is bent in the circumferential direction into a downward convex shape in Fig. 1 by the outer wall surface 22 of the upper forming roller 20 on the outlet side where it is pressed. As a result, after being bent once, it is bent in the opposite direction, and is conveyed into the reel 8 as an inwardly warped copper wire 3 with a large bending resistance.

[0019] The height level of the rotation center shaft 31 of the reel 8 is located at approximately the same height level as the height level of the copper wire 3 being fed to the lower forming roller 10 . Between the upper forming roller 20 and the reel 8, a pair of guide shafts 32, 33 that control and guide the position of the reel 8 in the winding width direction to a predetermined position are supported on the base 1 via a bracket 34 so as to be freely rotatable.

[0020] The reel 8 has short sides 82 and 83 and long sides 84 and 85 centered on a central axis of rotation 31, and receives a driving force from the motor 5 to rotate counterclockwise about the central axis of rotation 31 as shown in FIG.

[0021] The distance between the rotation center axis 31 of the reel 8 and the rotation center axis 21 of the upper forming roller 20 is basically constant. The speed (wire speed) of the copper wire 3 supplied to the reel 8, which rotates at a constant speed, varies depending on the rotation angle of the reel 8, which has short side surfaces 82, 83 and long side surfaces 84, 85.

[0022] FIG. 2 shows the state of the wire at different winding frame positions with different rotation angles. The contact position 81 of the copper wire 3 fed into the reel 8 rotating in the winding direction changes over time in the order of FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D, and FIG. 2A, and this sequence is repeated.

[0023] The shape of the copper wire 3 connecting the contact position 81 of the copper wire 3 being carried into the reel 8 with the reel 8 and the position (carry-out position) 24 where the copper wire 3 wound around the outer wall surface 22 of the upper forming roller 20 moves away from the outer wall surface 22 maintains an inward curvature when viewed from the rotation center axis 31 of the reel 8. The inward curvature shape of the copper wire 3 on the inlet side of the reel 8 basically changes over time in accordance with the rotation angle of the reel 8, for every 180 degrees of the rotation angle of the reel 8. In this embodiment, the height position of the rotation center shaft 31 of the reel 8 is set to the same level as the wire supply height level.

[0024] Next, the relationship between the rotation angle of the reel 8, the rotation position of the reel 8, the moving speed of the copper wire at the reel inlet, and the average moving speed of the copper wire will be described with reference to Fig. 3. Fig. 3 is an image diagram to help understand the present invention and does not show accurate values. The horizontal axis of Fig. 3 indicates the reel rotation angle from 0° to 180°. The upper part of Fig. 3 shows the reel rotation position corresponding to the reel rotation angle. Winding of the long side of the reel starts from rotational position 801, and as the angle advances, the copper wire becomes loose and the moving speed of the copper wire gradually decreases (wire speed reduction). The moving speed of the copper wire is further reduced via rotational position 802 of the reel. Winding of the long side of the reel continues from a rotational angle of 0° of the reel 8 to rotational position 803 where the moving speed of the copper wire becomes the lowest.

[0025] When switching from long side winding to short side winding, the tension of the copper wire increases rapidly as the angle advances, the moving speed of the copper wire increases rapidly (wire speed increase), and after passing through rotation position 804 and reaching the maximum speed of the copper wire, it moves to rotation position 805. Subsequently, similar changes in the winding state of the copper wire are repeated from the above rotation position 801.

[0026] As shown in Fig. 3, the moving speed of the copper wire at the entrance of the reel 8 changes depending on the positions 801, 802, 803, 804, and 805. The moving speed of the copper wire gradually decreases from the initial reel rotation angle position of 0°, reaching the minimum speed at rotation position 803, and then reaching the maximum moving speed on the way to rotation position 804. The average moving speed (average wire speed) of the copper wire is as shown in the figure. In general, the moving speed of the copper wire decreases during the long side winding period, and increases during the short side winding period.

[0027] In the first embodiment, the copper wire 3 is wound around the reel 8 so that at the reel entrance, the copper wire 3 is curved inward when viewed from the rotation center axis 31 of the reel 8. By utilizing the tendency of the copper wire 3 to bend radially inward, the bulging of the copper wire radially outward when viewed from the rotation center axis 31 of the reel 8 is reduced, thereby improving the accuracy and density of the aligned winding. Furthermore, according to the first embodiment, the inward curvature effect of the copper wire being brought into the reel entrance can be utilized to increase the speed at which the copper wire is moved to the reel, thereby achieving high-speed winding.

[0028] According to the first embodiment, when the copper wire is wound around the reel, the copper wire 3 on the inlet side of the reel 8 is deformed to be curved inward as viewed from the reel rotation center axis 31 so as to correspond to the rotation direction of the reel 8 and to counteract the bulge of the copper wire wound around the reel, so that the copper wire 3 discharged from the upper forming roller 20 corresponds to the rotation direction of the reel 8, and thus the copper wire 3 is wound around the reel 8.

[0029] According to the first embodiment, the copper wire 3 which starts to be wound around the lower forming roller 10 is first bent and deformed into an upward convex shape as shown in FIG. 1, and then is clamped between a pair of upper and lower forming rollers 10, 20, and then is bent a second time by the lower forming roller 20 in the opposite direction to the first bending deformation, resulting in a downward convex deformation (reverse bending deformation) as shown in FIG. 1, thereby improving the bending effect (inward warping effect). Therefore, even if the speed difference and acceleration / deceleration become large according to the aspect ratio of the reel 8, the copper wire 3 that maintains the inward warping deformation can be wound tightly around the reel 8 at high speed. In particular, even if slack occurs on the long side surfaces 84, 85 of the reel 8, the inward warping effect works to cancel out the bulge. This allows the winding width (stacking height) of the stacked windings to be reduced.

[0030] According to the coil winding device of this embodiment, when the wire 3 is wound in multiple layers, for example, 3 to 4 layers as shown in Fig. 10, around a rectangular reel 8 with a high aspect ratio b / a as shown in Fig. 9, the bulge of the coil wound around the reel is suppressed. Note that the numbers inside the wire 3 in Fig. 10 indicate the winding order of the wire to be wound around the reel 8. At the start of winding, the first layer is wound from one end of the reel to the other, and then the second layer is wound in the folding back direction, and this is repeated in sequence.

[0031] According to the coil winding device of the present embodiment, even if there is a fluctuation in tension in the wire being fed into the winding frame, the expansion of the winding width is suppressed, thereby realizing high-density winding in multiple layers. Furthermore, even if the moving speed of the wound wire is increased, high speed winding and aligned winding can be achieved with the swelling suppressed. When a fixed core is manufactured by assembling and arranging a plurality of winding frames on a circular arc, the winding width of a plurality of layers of windings wound around adjacent winding frames can be prevented from expanding in a radially outward direction as viewed from the central axis of rotation of the winding frames.

[0032] Second Embodiment A coil winding device according to a second embodiment is shown in FIGS. 4A and 4B. In the second embodiment, the rotation direction of the reel 8 is opposite to that of the reel in the first embodiment (counterclockwise), and rotates clockwise as shown in Fig. 4. The copper wire 3 entering the entrance of the reel 8 is deformed into an upward convex shape in Figs. 4A and 4B.

[0033] Fig. 4A shows the state of the rotation angle position of the reel where the speed (wire speed) of the copper wire being fed into the reel is the maximum speed, and Fig. 4B shows the state of the rotation angle position of the reel where the speed (wire speed) of the copper wire being fed into the reel is the minimum speed. In the figures, the same reference numerals are used for substantially the same components.

[0034] In the second embodiment, the rotation direction of the reel is opposite to that of the reel in the first embodiment (counterclockwise), and rotates clockwise as shown in Fig. 4. The copper wire entering the entrance of the reel 8 is deformed into an upward convex shape.

[0035] The rotation center axis 41 of the upper forming roller 40 is positioned horizontally eccentrically relative to the rotation center axis 51 of the lower forming roller 50, on the side away from the rotation center axis 31 of the reel 8 by a distance d3, and is positioned vertically eccentrically relative to the rotation center axis 51 of the lower forming roller 50 by a predetermined distance (the distance that appears in Figure 4).

[0036] The outer wall surface 42 of the upper forming roller 40 is formed as a flat surface in the roller width direction, similar to the outer wall surface 52 of the lower forming roller 50. The copper wire 3 is clamped from both sides at the contact points between the outer wall surface 42 of the upper forming roller 40 and the outer wall surface 52 of the lower forming roller 50.

[0037] The copper wire 3 formed by applying pressure from both sides of the copper wire 3 with the upper forming roller 40 and the lower forming roller 50 is bent in the circumferential direction into a downward convex shape in Fig. 4 by the outer wall surface 42 of the upper forming roller 40 on the inlet side where it is pressed, and is bent in the circumferential direction into an upward convex shape in Fig. 4 by the outer wall surface 52 of the lower forming roller 50 on the outlet side where it is pressed. As a result, after being bent once, it is bent in the opposite direction, and is conveyed into the reel 8 as an inwardly warped copper wire 3 with a large bending resistance. The height level of the rotation center shaft 31 of the reel 8 is located at approximately the same height level as the height level of the copper wire 3 being fed to the upper forming roller 40 .

[0038] In this embodiment, the height level position of the rotation center shaft 31 of the reel 8 is set at a lower level, a distance δ1 in the direction of gravity, than the highest point of the lower forming roller 50. In the present invention, in this embodiment, it is preferable that the height level position of the rotation center shaft 31 of the reel 8 is set at a level in the direction of gravity higher than the highest point of the lower forming roller 50. This is because the bending distance by the lower forming roller 50 becomes longer, and the inward warping effect of the copper wire is improved.

[0039] In the second embodiment, whether the wire is wound on the short side surface of the reel or on the long side surface of the reel, the wire is wound with an inward curvature when viewed from the center axis of rotation of the reel, so that bending resistance acts in a direction that suppresses bulging, resulting in the winding being formed closely.

[0040] Third embodiment A third embodiment is shown in FIGS. The third embodiment is similar to the first embodiment in that the outer wall surface 22 of the upper forming roller 20 is a flat surface. The outer wall surface 62 of the lower forming roller 60 has a V-shaped groove 63 formed in the center of the flat surface over the entire circumference in the circumferential direction.

[0041] In the third embodiment, the arrangement of the rotation center shaft 21 of the upper forming roller 20 and the rotation center shaft 61 of the lower forming roller 60 is the same as that in the first embodiment. The other configurations of the third embodiment are the same as those in the first embodiment.

[0042] The copper wire 300 is shaped by applying pressure from both sides of the copper wire 300 by the lower forming roller 60 and the upper forming roller 20, and is bent in the circumferential direction into an upward convex shape in Fig. 5 by the outer wall surface 62 of the lower forming roller 60 on the inlet side where it is pressed, and is bent in the circumferential direction into a downward convex shape in Fig. 5 by the outer wall surface 22 of the upper forming roller 20 on the outlet side where it is pressed. As a result, after being bent once, it is bent in the opposite direction, and is conveyed into the reel 8 as an inwardly warped copper wire 300 with a large bending resistance.

[0043] According to the third embodiment, as in the first embodiment, the copper wire has an inwardly curved shape when wound around a reel due to a bending process in the opposite direction to the bending process applied to the wire by a pair of eccentric rollers.

[0044] When the V-groove 63 is formed on the outer wall surface 62 of the lower forming roller 60, the bending resistance of the copper wire 300 conveyed from the upper forming roller 20 is relatively increased, and the tendency to maintain the inward curvature is increased. In the third embodiment, due to the clamping pressure applied between the lower roller 60 for forming and the upper roller 20 for forming, the copper wire 300 carried out from the upper roller 20 for forming has a circular basic shape in terms of the cross-sectional shape as shown in FIG. 6B, and inclined surfaces 302 and 303 corresponding to the V-groove 63 are formed, and a flat surface 301 corresponding to the outer wall surface 22 is formed.

[0045] According to the third embodiment, the winding wire 300 wound around the winding frame 8 in multiple layers is not only wound closely in the radially inward direction due to the inward warping effect like the winding state 57 shown in FIG. 7B compared to the winding state without forming (reference numeral 55 shown in FIG. 7A), but also relatively flatly laminated. Here, the winding state without forming is manufactured by, for example, the coil winding device shown in FIG. 8. In this coil winding device, the rotation center axis 37 of the lower roller 36 for forming and the rotation center axis 39 of the upper roller 38 for forming are equidistant (d1 = 0) from the rotation center axis 31 of the winding frame 8 and are arranged at positions without eccentricity in the horizontal direction. In this coil winding device, the copper wire is not bent and formed, and no bending process is performed.

[0046] As shown in FIG. 7, when comparing the three-layer state without forming (see FIG. 7A) indicated by reference numeral 55 and the three-layer state with forming according to the third embodiment (see FIG. 7B) indicated by reference numeral 57, The winding cross-sectional height x2 of the first layer of the winding with forming in the third embodiment is smaller (x2 < x1) than the height x1 of the winding cross-section without forming in the first layer. The width y2 of the winding cross-section of the first layer of the winding with forming in the third embodiment is larger (y2 > y1) than the width y1 of the winding cross-section without forming in the first layer.

[0047] The magnitudes of the differences h1 in the winding cross-sectional height of the first layer of the laminated windings, h2 in the winding cross-sectional height of the second layer, and h3 in the winding cross-sectional height of the third layer have a relationship of h3 > h2 > h1. From this, it can be seen that as a result of the forming according to the third embodiment, the swelling of the winding height in the three-layer state wound around the winding frame is suppressed compared to the case without forming.

[0048] The thickness of the windings wound in an aligned manner in multiple layers around a bobbin is smaller than the thickness of the windings wound without shaping as shown in FIG. 7A, as shown in FIG. 7B for the windings wound in an aligned manner in multiple layers with shaping according to the third embodiment. According to the coil winding device of the third embodiment, the thickness of the winding wound around the bobbin can be reduced, which is expected to increase the number of turns of the winding in the gaps between adjacent teeth of the fixed core after assembly, and thus to improve performance.

[0049] (Fourth embodiment) A fourth embodiment is shown in FIG. In this embodiment, the height level position of the rotation central shaft 31 of the reel 8 is set at a level that is a distance δ2 away from the lowest point of the upper forming roller 20 in the antigravity direction. In the present invention, in this embodiment, it is preferable that the height level position of the rotation central shaft of the reel is set at a level that is away from the lowest point of the upper forming roller in the antigravity direction. This is because the bending distance by the upper forming roller becomes longer, and the inward warping effect of the copper wire is improved.

[0050] (Other embodiments) In the first embodiment, the height level position of the rotation center shaft 31 of the reel 8 is located at approximately the same height level position as the height level position of the copper wire fed to the lower forming roller 10. In the present invention, the height level position of the rotation center shaft 31 of the reel 8 may be either higher or lower than the height level position of the copper wire carried (supplied) to the lower forming roller 10. In the present invention, in the embodiment shown in Fig. 1, when the reel rotates counterclockwise, it is preferable that the reel is at a level higher in the antigravity direction than the lowest point of the upper forming roller 20 in Fig. 1. This has a large effect of suppressing the expansion of the copper wire when the wire is wound around the reel due to the inward warping of the copper wire.

[0051] Next, the present invention will be described in a comparative example. (Comparative form 1) Comparative Example 1 is shown in FIG. 8 has a configuration in which the copper wire 3 is clamped by a pair of rollers 36, 38 whose rotation centers are spaced the same distance apart from each other. In this configuration, the copper wire 3 supplied to the reel 8 is not bent. Therefore, the copper wire wound around the reel tends to bulge radially outward. In contrast, in the present invention, the copper wire carried into the reel is curved inward at the reel entrance when viewed from the center of rotation of the reel, so that the copper wire wound around the reel is prevented from bulging radially outward.

[0052] According to the experimental results, in data 1 of the comparative embodiment 1 without the inward warping, the winding width shown in Fig. 11 was D3 = 14.62 mm in the width dimension of 3 layers D3 shown in Fig. 10. On the other hand, in data 1 of the first embodiment with the inward warping, the winding width shown in Fig. 11 was D3 = 13.99 mm in the width dimension of 3 layers D3 shown in Fig. 10. In data 2 of the comparative embodiment 1 without the inward warping, the winding width shown in Fig. 11 was D4 = 16.57 mm with the width dimension of 4 layers D4 shown in Fig. 10. On the other hand, in data 2 of the first embodiment with the inward warping, the winding width shown in Fig. 11 was D4 = 15.91 mm with the width dimension of 4 layers D4 shown in Fig. 10.

[0053] (Comparative form 2) Comparative embodiment 2 is the above-mentioned Patent Document 1, which discloses a configuration in which a wire bending device is disposed upstream of the winding form, the device including a first backup roller and a second backup roller rotatably supported on a machine frame at a fixed interval, and a reverse-camber roller that simultaneously clamps the wire between the first backup roller and the second backup roller, and applies plastic deformation to the wire by curving in the opposite direction to the swelling direction of the wire that attempts to curve and bulge from the straight side of the winding form.

[0054] Comparing the present invention with the comparative embodiment 2, there are the following differences. Comparative Example 2 is configured to bend and deform the wire by providing a third roller, a reverse-cambered roller, in addition to the first and second back-up rollers. Comparative Example 2 does not have a configuration (function) of clamping the wire at the same contact point between the first backup roller and the second backup roller.

[0055] Comparative Example 2 is configured such that the speed difference and acceleration / deceleration become large according to the aspect ratio of the bobbin, making it difficult to wind the wire around the bobbin at high speed. In comparative example 2, the tension fluctuates when the layers of the wire wound around the reel are switched (from nth layer to n+1th layer), making it more difficult to control.

[0056] In contrast, the present invention has the following features in comparison with Comparative Example 2. In the present invention, the positional relationship of the rotational center axes of a pair of forming rollers that press the wire from both sides between the reel and the wire supply source is specified to be in an eccentric position. Due to the arrangement of the rotational center axes of the pair of forming rollers, the wire is bent (first bending deformation) and then reversely bent (second time), and the inwardly warped wire is wound around the reel. The present invention does not include rollers corresponding to the first and second backup rollers.

[0057] The present invention suppresses the expansion of the wire when it is wound around the reel, without providing a third roller (corresponding to the reverse-warped roller 15 in Comparative Example 2). The present invention performs a two-stage bending process with a simple configuration, in which a wire material is bent by a first roller and then bent in the opposite direction to the first bending deformation by a second roller. The present invention does not provide a third roller (the reverse-warped roller in Prior Art Document 1) at the entrance of the reel, but provides a pair of rollers that simultaneously pinch the wire between both surfaces of the pair of upper and lower rollers. The present invention can prevent inward bowing deformation of the wire at the inlet of the reel when tension varies, and suppress bulging when wound around the reel, even when the reel has a high aspect ratio and the wire is moving at a high speed.

[0058] Next, in the first embodiment, both the lower forming roller surface and the upper forming roller surface are flat surfaces. (Various roller surfaces of upper and lower rollers for forming) In the present invention, various modified examples are shown for the first roller and the second roller, which correspond to the lower forming roller and the upper forming roller.

[0059] FIG. 12 shows an example in which the outer wall surface 22 of the upper forming roller 20 and the outer wall surface 12 of the lower forming roller 10 are both flat surfaces. FIG. 13A shows an example of a roller surface in which the outer wall surface 22 of the upper forming roller 20 is a flat surface, and the outer wall surface 12 of the lower forming roller 10 has a V-shaped groove 63 in the center. FIG. 13B shows an example in which the outer wall surface 22 of the upper forming roller 20 and the outer wall surface 12 of the lower forming roller 10 both have V-shaped grooves 63, 64. FIG. 14A shows an example of a roller surface in which the outer wall surface 22 of the upper forming roller 20 is a flat surface and the outer wall surface 12 of the lower forming roller 10 has a U-shaped groove 65 . FIG. 14B shows an example of roller surfaces in which the outer wall surface 22 of the upper forming roller 20 and the outer wall surface 12 of the lower forming roller 10 both have U-shaped grooves 65, 66.

[0060] Fig. 15 shows a modified example of the level of the rotation axis of the reel in the first embodiment. The modified example shown in Fig. 15 shows an example in which the level of the rotation axis 31 of the reel 8 is set at a position (antigravity direction) higher than the lowest point of the outer wall surface of the upper forming roller 20 by a distance δ2. The value of the distance δ2 is preferably a positive value.

[0061] In the disclosure of the present invention, a coil winding device includes a base, a winding form (8) rotatably supported on the base and winding a wire (3) supplied from a wire supply source (2), a drive source (5) that drives and rotates the winding form, and a lower forming roller (10) and an upper forming roller (20) that apply an external force to the wire supplied to the winding form to wind and shape the wire, The forming upper roller and the forming lower roller may be arranged such that one of the roller rotation central axes (21) is eccentric to the rotation central axis (11) of the other roller by a distance (d1, d2) toward the rotation center of the reel, and after bending deformation is applied to the wire by one roller, the wire is pressed between the first roller and the second roller, and then a reverse bending deformation in the opposite direction to the bending deformation is applied by the other roller. In this manner, the wire on the inlet side of the reel is deformed inward (in an upward convex or downward convex shape) when viewed from the rotation central axis of the reel so that the wire discharged from the forming roller corresponds to the rotation direction of the reel, thereby canceling out any bulging of the wire wound around the reel.

[0062] In the present disclosure, the coil winding device may be configured to include a tension applying unit (4) that applies tension between the wire supply source and the upper and lower forming rollers in accordance with the degree of slackness of the wire. In the present disclosure, the coil winding device may be configured to include guide portions (32, 33) between the winding frame and the upper forming roller and the lower forming roller for guiding (regulating) the position of the wire material supplied to the winding frame in the width direction of the winding frame.

[0063] In the present disclosure, the coil winding device may be configured such that the outer wall surface (12) of the first roller and the outer wall surface (22) of the second roller are flat surfaces. In the present disclosure, the coil winding device may be configured such that one or both of the outer wall surface (12, 60) of the first roller and the outer wall surface (22) of the second roller have a V-groove (63, 64) for guiding the wire. In the present disclosure, the coil winding device may be configured such that one or both of the outer wall surface (12) of the first roller and the outer wall surface (22) of the second roller have U-shaped grooves (65, 66) for guiding the wire.

[0064] In the disclosure of the present invention, the coil winding method is a coil winding method for winding a wire (3, 300) around a rotatably driven winding form, and includes a step of applying a bending deformation to the wire supplied to the winding form (8) with one roller (10, 40, 60) of a pair of forming rollers for bending the wire, and a step of applying a reverse bending deformation in a direction opposite to the bending deformation with the other roller (20, 50) of the pair of forming rollers, The step of applying a reverse bending deformation to the wire by the other roller may be characterized as a step of deforming the wire on the inlet side of the reel into an inward bow (in an upwardly convex or downwardly convex shape) (as viewed from the central axis of rotation of the reel) so as to counteract bulging of the wire wound around the reel.

[0065] In the present disclosure, the coil winding method may be characterized in that the step before the bending deformation includes a step of applying tension to the wire. [Explanation of symbols]

[0066] 1 base, 2 Bobbin (wire supply source), 3 Copper wire (wire material), 4 tension control device (tension applying unit), 8 reel frames, 9 Warping device, 10 Lower forming roller (first roller), 11 Rotational axis, 20 Upper forming roller (second roller), 21 Rotational axis, 31 Rotational axis, 32, 33 Guide shaft (guide part), 40 Upper forming roller (first roller), 50 Lower forming roller (second roller), 60 forming lower roller (first roller), 63, 64 V groove, 300 Copper wire (wire material), 301 plane, 302, 303 Slopes.

Claims

1. A base (1), a reel (8) that is rotatably supported on the base and that winds the wire (3, 300) supplied from a wire supply source (2); A drive source (5) for rotating the reel; a first roller (10, 40, 60) that is rotatably supported on the base and that shapes the wire at an inlet side of the reel; a second roller (20, 50) that is rotatably supported on the base and that applies a clamping pressure between the first roller and the second roller to shape the wire at an inlet side closer to the reel than the first roller, a bending deformation is applied by an external force of the first roller, a pinching pressure is applied between the first roller and the second roller, and then a reverse bending deformation is applied in a direction opposite to the bending direction of the bending deformation by an external force of the second roller; a coil winding device in which the rotational central axes (11, 21, 31, 41, 51, 61) of the first roller and the second roller are arranged at positions eccentric by a distance (d1, d2) so as to give an inward curvature to the wire being carried into the reel.

2. 2. The coil winding device according to claim 1, further comprising a tension applying section (4) for applying tension to the wire between said wire supply source and said upper forming roller and said lower forming roller.

3. 3. The coil winding device according to claim 1, further comprising guide portions (32, 33) between the winding frame and the upper forming roller and the lower forming roller for regulating a position in a width direction of the winding frame of the wire material supplied to the winding frame.

4. 2. The coil winding device according to claim 1, wherein the outer wall surface (12) of the first roller and the outer wall surface (22) of the second roller are flat surfaces.

5. 2. The coil winding device according to claim 1, wherein one or both of the outer wall surface (12, 60) of the first roller and the outer wall surface (22) of the second roller have a V-shaped groove (63, 64) for guiding a wire.

6. 2. The coil winding device according to claim 1, wherein one or both of the outer wall surface (12) of the first roller and the outer wall surface (22) of the second roller have a U-shaped groove (65, 66) for guiding a wire.

7. A coil winding method for winding a wire (3, 300) around a rotating winding form, comprising the steps of: a step of bending the wire rod supplied to the reel (8) with one roller (10, 40, 60) of a pair of forming rollers for bending the wire rod; and applying a reverse bending deformation in a direction opposite to the bending deformation by the other roller (20, 50) of the pair of forming rollers, The step of applying a reverse bending deformation to the wire by the other roller is a step of deforming the wire on the entrance side of the reel into an inward bow so as to counteract the bulge of the wire wound around the reel.

8. 8. The coil winding method according to claim 7, further comprising a step of applying tension to the wire before the bending deformation.

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