Wire coil manufacturing method

Abstract

To increase a space factor and reduce transportation costs of a wire.SOLUTION: A loose coil 43 is manufactured by: a base coil part formation process in which a wire W is wound, and a cone-shaped base coil part 41 with a top face downwardly inclined toward a midship part is formed; and a laminated coil part formation process in which the wire W is wound along the inclined top face of the base coil part 41, and a laminated coil part 42 is formed on an upper side of the base coil part 41.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a wire coil by winding a metal wire such as a copper wire. [Background technology]

[0002] Coils manufactured by winding metal wire such as copper wire include compact coils and loose coils. As described in Patent Document 1, compact coils are manufactured by winding the wire around a winding jig with a tapered outer surface, pressing it axially with a coil compactor, and binding it with a metal band. On the other hand, loose coils are manufactured by unwinding the wire from a coiler and winding it into a coil shape on a pallet. Multiple poles made of rod material are attached to the outer periphery of the pallet, and loose coils are arranged within the area surrounded by the multiple poles so that their outer peripheries come into contact with multiple ports. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-114132 Summary of the Invention [Problem to be solved by the invention]

[0004] Because compact coils are pressed in the axial direction, they have a higher space factor for the wire than loose coils, but they require the installation of winding jigs and coil compactors, which inevitably increases the coil manufacturing costs.In addition, a single compact coil is smaller than a loose coil, so it requires more transportation by lift or the like to load it onto a transport truck, etc., which inevitably increases the transportation costs.

[0005] In contrast, loose coils do not require equipment such as coil compactors, but have the disadvantage of a low wire space factor.If the wire space factor of loose coils can be increased, the weight of coils that can be loaded onto one pallet can be increased, making it possible to reduce the transportation costs of coils.

[0006] The present invention has been devised in view of the above problems, and has an object to provide a loose coil that can increase the space factor of the wire and reduce the transportation cost of the coil. [Means for solving the problem]

[0007] One embodiment of a wire coil manufacturing method involves winding, onto a pallet, wire that is unwound in a spiral shape from a nozzle that rotates around a vertical central axis of rotation, to produce a loose coil. The method includes a base coil portion forming process in which the wire is wound to form a funnel-shaped base coil portion on the top surface of the pallet, the base coil portion having an upper surface that slopes downward toward the center of the pallet, and a stacked coil portion forming process in which the wire is wound along the sloped upper surface of the base coil portion to form a stacked coil portion above the base coil portion, the upper surface of which slopes downward toward the center. [Effects of the Invention]

[0008] The loose coil according to the present invention has a base coil portion that is shaped like a mortar with an upper surface that slopes downward, and a laminated coil portion that is formed by winding wire along the upper surface of the base coil portion. This increases the space factor of the wire, increases the weight of coils that can be loaded onto one pallet, and reduces the transportation costs of the coils. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 10 is a front view showing the winding machine in a state in which the wire fed from the coiler is wound to form an inner coil portion. [Figure 2](A) is a view taken along line AA in Fig. 1, showing the bottom surface of the coiler, and (B) is a view taken along line BB in Fig. 1, showing the plane of the inner coil portion. [Figure 3] FIG. 10 is a front view showing the inner coil portion in a state where it has been dropped onto a pallet from the opening / closing shutter. [Figure 4] 10 is a front view showing an initial coil section formed by assembling an outer coil section to the outside of an inner coil section and an outer coil section. FIG. [Figure 5] FIG. 10 is a cross-sectional view of the coil showing the state in which the base coil portion is being formed on the initial coil portion. [Figure 6] FIG. 10 is a partially cutaway front view showing a loose coil in a state in which a wire is wound on the upper side of a base coil portion to form a laminated coil portion. [Figure 7] FIG. 7 is a plan view of the loose coil shown in FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0010] <Coiler-type winding machine> Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a front view of a coiler-type winding machine 10 (hereinafter simply referred to as "winding machine 10"), also known as a coiler, which is used to produce loose coils, which are wire coils. The winding machine 10 is disposed above a conveyor 12, such as a roller conveyor, for transporting a pallet 11 serving as a loading platform. A copper or copper alloy wire W is supplied to the winding machine 10. The wire W is produced by supplying molten copper or copper alloy to a continuous casting machine and then rolling the wire ingot from the continuous casting machine using a rolling mill. The loose coil produced on the pallet 11 by the winding machine 10 is transported to a wire drawing process where the wire diameter is uniformed.

[0011] The pallet 11 is formed of a square frame or plate material, and has a plurality of rods, or poles 13, attached to its outer periphery at intervals in the circumferential direction. As shown in Figure 2(B), six poles 13 are attached to the pallet 11, and the imaginary lines drawn inside these poles 13 roughly correspond to the outer periphery of the loose coil.

[0012] The winding machine 10 has a rotating body 15 mounted on a support base 14, and the rotating body 15 is mounted on the support base 14 so as to be freely rotatable by a plurality of guide rollers 16 provided on the support base 14. In order to drive the rotating body 15, an electric motor 17 is attached to the support base 14, and a drive roller 18 pressed against the outer circumferential surface of the rotating body 15 is driven to rotate by the electric motor 17, and the driving roller 18 drives the rotating body 15 to rotate.

[0013] A box 22 equipped with pinch rollers 21 is attached to a support stand 14, and the wire rod W that has passed through the pinch rollers 21 is paid out downward from the tip of a nozzle 23 attached to a rotor 15. As shown in FIG. 2(A), the tip of the nozzle 23 is located at a constant radius R from the central axis of rotation O of the rotor 15, and the length of the wire rod W that is paid out per unit time from the tip of the nozzle 23, i.e., the payout speed V, is set to a constant value. The rotation speed S of the rotor 15 can be changed by an electric motor 17. Note that the guide rollers 16 and the drive roller 18 are not shown in FIG. 2(A).

[0014] As shown in Fig. 1, an opening / closing shutter made up of two opening / closing members 24, 24 is disposed below the winding machine 10. The two opening / closing members 24, 24 are movable toward and away from each other, and each opening / closing member 24, 24 is supported movably on a support base (not shown). Note that although Figs. 1 to 6 have been described as an opening / closing shutter made up of two opening / closing members 24, 24, the present invention is not limited to this, and the opening / closing shutter may be made up of, for example, six opening / closing members.

[0015] <Initial coil formation process> FIG. 1 shows a state in which wire rod W is being wound to form an inner coil portion 31. The inner coil portion 31 is formed by unwinding wire rod W onto the open-close members 24 at a constant speed from a nozzle 23 that rotates around a rotation center axis O while the open-close members 24 are closed. As shown in FIG. 1, the wire rod W is spirally wound on the open-close members 24 to form the inner coil portion 31. When the inner coil portion 31 is being formed, the pallet 11 on which a loose coil has already been produced is carried out from below the open-close members 24 by the conveyor 12, and an empty pallet 11 (i.e., no wire rod W is wound on it) is carried below the open-close members 24 as shown in FIG. 1. In this way, the inner coil portion 31 can be formed even while the empty pallet 11 is moving, allowing for continuous production of loose coils.

[0016] In the inner coil portion forming process, the wire W is spirally wound from the radially inner periphery side toward the radially outer periphery side, and then spirally wound from the radially outer periphery side toward the radially inner periphery side so as to be stacked on top of the wound wire W. By repeating this process multiple times, the inner coil portion 31 is formed. The winding direction when winding the wire W spirally may be either clockwise or counterclockwise.

[0017] 2(B), the outer diameter d2 of the inner coil portion 31 is smaller than the maximum outer diameter of the region of the pallet 11 surrounded by the six poles 13, and the inner coil portion 31 is formed inside the opening / closing members 24, 24 in a region corresponding to the radial center (hereinafter also referred to as the center) of the pallet 11. The inner coil portion 31 is annular and has an outer peripheral surface 31a and an inner peripheral surface 31b, and a hollow hole 30 is formed inside the inner peripheral surface 31b.

[0018] As shown in FIG. 3, by opening the opening / closing members 24, 24, the inner coil portion 31 is dropped toward the center of the pallet 11 and placed in the center on the pallet 11. Following this dropping step, as shown in FIG. 4, the wire rod W is wound around the outside of the inner coil portion 31 to form the outer coil portion 32. In this way, an initial coil portion 33 consisting of the inner coil portion 31 and the outer coil portion 32 is manufactured. When forming the outer coil portion 32, the wire rod W is wound spirally from the radially inner circumferential side to the radially outer circumferential side, and then wound spirally from the radially outer circumferential side to the radially inner circumferential side so as to be stacked on top of the wound wire rod W. By repeating this process multiple times, the outer coil portion 32 having a height equivalent to that of the inner coil portion 31 is formed.

[0019] In Fig. 4, diameter d1 is the inner diameter of the hollow space of the inner coil portion 31, and diameter d2 is the outer diameter of the inner coil portion 31. The outer peripheral surface of the initial coil portion 33, i.e., the outer peripheral surface 32a of the outer coil portion 32, comes into contact with the pole 13, thereby preventing the initial coil portion 33 from collapsing. In Fig. 4, all of the wire rods constituting the outer peripheral portion of the initial coil portion 33 are shown aligned and in substantial contact with the pole 13, but some of the wire rods W may not come into contact with the pole 13.

[0020] As shown in Fig. 4, the swirl speed S of the nozzle 23 when forming the outer coil portion 32 is set slower than the swirl speed S of the nozzle 23 when forming the inner coil portion 31 as shown in Fig. 1. In other words, the swirl speed of the nozzle 23 when forming the radially outer portion of the coil portion is set slower than the swirl speed of the nozzle 23 when forming the radially inner portion. When the swirl speed S of the wire rod W that is paid out at a constant payout speed V is slowed, the wire rod W is paid out radially outward more than when the swirl speed S is fast, and the outer coil portion 32 is formed. In this way, the winding diameter of the wire rod W is adjusted by the swirl speed S of the nozzle 23.

[0021] The rotation speed S of the nozzle 23 may be changed stepwise in accordance with the diameter of the coil, or may be changed continuously and steplessly.

[0022] <Base coil forming process> FIG. 5 shows the state after the base coil forming step of forming the base coil portion 41 on the initial coil portion 33 is completed. The base coil portion 41 is formed by winding the wire W in more layers at the outer periphery than at the center. As shown in FIG. 5, the base coil portion 41 has an outer periphery surface 41a extending vertically along the pole 13 and an upper surface 41b inclined downward at an angle θ from the outer periphery toward the inner periphery in the radial direction, forming a mortar shape. The inner periphery surface of the base coil portion 41 roughly corresponds to the inner periphery surface 31b of the inner coil portion 31.

[0023] In FIG. 5, only a part of the wire W for forming the coil is shown as a circular cross section, and the other parts are hatched, with the wire W not being shown.

[0024] <Laminated coil part forming process> By winding the wire W on the inclined upper surface 41b of the base coil portion 41 along the upper surface 41b, a laminated coil portion 42 is formed on the upper side of the base coil portion 41, as shown in Fig. 6. Fig. 6 shows the state when the winding of the laminated coil portion 42 is completed, that is, when the laminated coil portion forming step is completed.

[0025] The outer peripheral surface 42a of the laminated coil portion 42 is substantially flush with the outer peripheral surface 41a of the base coil portion 41. The laminated coil portion 42 is formed by winding the wire rod W radially, layer by layer, so that the wire rod W is stacked along the upper surface 41b of the base coil portion 41. The laminated coil portion 42 is formed with multiple layers of wire rod W on the upper surface 41b of the base coil portion 41. That is, the upper layer coils constituting the laminated coil portion 42 are formed on the upper surface 42b inclined at an angle θ to the lower layer coils. Each coil piece constituting the laminated coil portion 42 is wound around the upper surface of the cone-shaped coil by the wire rod W of the lower coil piece. This prevents the wire rod W falling onto the upper surface from bouncing outward in the radial direction, and the wire rod W of the laminated coil portion 42 bites into the upper surface of the cone-shaped coil, thereby increasing the space factor of the base coil portion 41 and the laminated coil portion 42. Furthermore, the cross-sectional shape, i.e., the packaging shape, of the laminated coil portion 42 is improved, and deformation of the packaging shape is also suppressed.

[0026] According to experiments conducted by the present inventors, it has been found that a downward inclination angle θ between the upper surface 41 b of the base coil portion 41 and the cone-shaped upper surface 42 b of the laminated coil portion 42 should be set in the range of 10° to 30°, in order to prevent the wire material W from jumping or shifting during winding of the laminated coil portion 42 and to achieve an improvement in the space factor.

[0027] FIG. 6 shows the outer peripheral surface of a loose coil 43 consisting of an initial coil portion 33, a base coil portion 41, and a laminated coil portion 42, with the upper portion of the laminated coil portion 42 partially cut away and shown by hatching.

[0028] In this way, even when forming the base coil portion 41 and the stacked coil portion 42, the rotation speed of the nozzle 23 when forming the radially outer portion of the coil portion is set to be continuously or stepwise slower than the rotation speed of the nozzle 23 when forming the radially inner portion.

[0029] When forming the laminated coil portion 42, the rotation speed of the nozzle 23 is changed depending on whether it is the lower layer laminated coil portion 42 or the upper layer laminated coil portion 42 in Fig. 6. The upper layer laminated coil portion 42 is closer to the nozzle 23 than the lower layer laminated coil portion 42, so the rotation speed of the nozzle 23 is set slower in order to spread the wire W in the radial direction more than the lower layer laminated coil portion 42. In other words, the rotation speed of the nozzle 23 when forming the upper layer laminated coil portion 42 is set slower than the rotation speed of the nozzle 23 when forming the lower layer laminated coil portion 42. The change in speed may be continuous or stepwise.

[0030] The upper surface of the loose coil 43 is formed with an upper surface 42b that is inclined downward from the radially outer side to the radially inner side (or upward from the radially inner side to the radially outer side) in correspondence with the upper surface 41b of the base coil portion 41. In this way, by maintaining the upper surface of the loose coil 43, i.e., the upper surface 42b of the laminated coil portion 42, in a state inclined at a predetermined angle θ in the radial direction, collapse of the loose coil 43 can be suppressed.

[0031] That is, the manufactured loose coil 43 has the wire rod W wound up to a predetermined height, and the wire rod W exposed above it is wound in a state of being inclined at a predetermined angle θ along the radial direction. In particular, when the predetermined angle θ of the loose coil 43 is in the range of 10° to 30°, the wire rod W is prevented from jumping or shifting during transportation by a lift or a transport truck, and the load is less likely to collapse.

[0032] When the production of the loose coil 43 is completed, the open-close members 24, 24 are closed as shown in Fig. 6, and the wire rod W is cut. The wire rod W may be cut by an operator using a cutting jig, or may be cut automatically. The pallet 11 with the loose coil 43 loaded thereon is carried out by the conveyor 12, and a new, empty pallet 11 is carried in below the open-close members 24, 24 by the conveyor 12. During this carrying-out and carrying-in process, the wire rod W is wound on the closed open-close members 24, 24, and production of the next inner coil section 31 begins, and loose coils 43 are continuously produced.

[0033] 7 is a plan view of the loose coil 43 shown in Fig. 6, in which the outer diameter D of the loose coil 43 corresponds to the outer diameter D of the initial coil portion 33, and the inner diameter of the hollow hole 30 corresponds to the inner diameter d1 of the inner coil portion 31. The wire W that forms the inner peripheral surface of the hollow hole 30 is omitted from Figs. 5 and 6.

[0034] The loose coil 43 described above has the initial coil portion 33 which is the lowest coil portion, but it is also possible to make the loose coil 43 comprised of a base coil portion 41 and a stacked coil portion .

[0035] <Improvement of space factor> The loose coil 43 has a base coil portion 41 and a laminated coil portion 42 wound on the upper side thereof. The laminated coil portion 42 is laminated along an upper surface 41b of the base coil portion 41, which is inclined like a mortar, and an upper laminated coil portion is laminated on an upper surface 42b of the laminated coil portion 42, which is inclined like a mortar. Therefore, the coil pieces of the base coil portion 41 and the laminated coil portion 42 are combined with each other, thereby increasing the space factor of the wire material W.

[0036] In conventional manufacturing methods, wire is wound spirally to form horizontally layered coils, which are then stacked on top of each other. In contrast, in the present invention, the laminated coil portion 42 is formed on a sloping cone-shaped surface, so that the coil pieces are combined with each other to form a loose coil of the same height as a loose coil formed by conventional manufacturing methods, but the weight of the loose coil 43 is increased. Therefore, the load weight (= coil weight) of the loose coil 43 mounted on the pallet 11 can be increased, and the transportation cost of the loose coil 43 can be reduced.

[0037] Furthermore, when the space factor of the wire rod W in the loose coil 43, i.e., the wire space factor, is increased, the wire rod W constituting the coil portion does not shift or bounce during transportation, thereby suppressing the occurrence of external damage to the wire rod W due to friction. In addition, since the loose coil 43 has a good wire space factor, it is possible to suppress the occurrence of tangled defects of the wire rod W when the wire rod W is drawn out from the loose coil 43 in the subsequent wiredrawing process.

[0038] The present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the spirit of the present invention. For example, although the top surface 41b of the base coil portion 41 and the top surface 42b of the laminated coil portion 42 are linear, the top surfaces 41b and 42b may be concave or convex as long as the imaginary lines connecting the outer periphery and the inner periphery of the top surfaces 41b and 42b are in the range of the inclination angle θ. [Explanation of symbols]

[0039] 10...coiler-type winding machine, 11...pallet, 12...conveyor, 13...pole, 14...support base, 15...rotating body, 17...electric motor, 23...nozzle, 24...opening / closing member, 30...hollow hole, 31...inner coil portion, 32...outer coil portion, 33...initial coil portion, 41...base coil portion, 42...stacked coil portion, 43...loose coil.

Claims

1. A method for manufacturing a wire coil, comprising winding a wire that is spirally fed from a nozzle that rotates around a vertical rotation center axis on a pallet to manufacture a loose coil, comprising: The wire rod is a copper or copper alloy wire rod produced by rolling a wire rod ingot supplied from a continuous casting machine using a rolling mill, an inner coil portion forming step of winding the wire rod on an opening / closing shutter arranged above the pallet to form an inner coil portion; a dropping step of dropping the inner coil unit from the opening / closing shutter onto the pallet; an initial coil portion forming step of forming an outer coil portion by winding the wire rod around the outer side of the inner coil portion dropped onto the pallet, thereby forming an initial coil portion consisting of the inner coil portion and the outer coil portion; a base coil portion forming process in which the wire is wound around the initial coil portion to form a base coil portion having a cone shape on the upper surface of the pallet, the upper surface of which is inclined downward toward the center of the pallet; a laminated coil portion forming step of winding the wire along the inclined upper surface of the base coil portion to form a laminated coil portion above the base coil portion, the upper surface of which is inclined downward toward the center portion, In the inner coil portion forming process and the initial coil portion forming process, the wire material unwound from the nozzle at a constant speed is spirally wound from the radial inner side to the radial outer side so as to be stacked on top of the wound wire material, and this is repeated multiple times in this method for manufacturing a wire coil.

2. 2. The method for manufacturing a wire coil according to claim 1, a coil winding section for winding a wire rod coil material to a first end of the coil winding section, the first end of the coil winding section being inclined downward toward the center portion of the coil winding section;

3. 3. The method for manufacturing a wire coil according to claim 1 or 2, The wire is fed out from the nozzle at a constant speed; a nozzle rotating speed when forming a radially outer portion of the base coil portion or the stacked coil portion is slower than a nozzle rotating speed when forming a radially inner portion of the base coil portion or the stacked coil portion, and the wire is fed out from the nozzle.

4. 4. The method for manufacturing a wire coil according to claim 3, wherein the rotation speed of the nozzle is changed stepwise or continuously depending on the diameter of the base coil portion or the stacked coil portion.

5. 5. The method for manufacturing a wire coil according to claim 3 or 4, a nozzle rotating speed when forming an upper side of the stacked coil portion being slower than a nozzle rotating speed when forming a lower side of the stacked coil portion, and the wire is fed out of the nozzle.

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