JP2006261578A - Method of manufacturing large-current noise filter and coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a large-current noise filter and a coil in which the coil is easily manufactured, manufacturing costs is reduced, and electric insulation is sufficiently ensured without damaging a straight-angle wire during manufacturing. <P>SOLUTION: A core 40 includes a middle leg 46 and an outer leg 48 extending from a base 44 in the same direction. A coil 70 is formed by edge-wise winding of a straight-angle wire, and includes a tubular coil 72 along with a side face of the middle leg 46 and extractions 74 extending from both ends of the coil 72, respectively. The extractions 74 are connected to a terminal 21. The coil 70 is juxtaposed in the extending direction of the middle leg 46 in the state of inserting the coil 72 into the middle leg 46. The middle leg 46 presents a long circular shape on a cross section vertical to the extending direction of the middle leg 46 and the outer leg 48, and a cross-sectional area of the middle leg 46 is larger than that of the outer leg 48. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a large current noise filter and a method for manufacturing a coil.

As one type of conventional large current noise filters, for example, as described in Patent Document 1, a filter having a spectacle-shaped winding (coil) made of a rectangular wire having a rectangular cross section or a trapezoidal cross section is known. .
JP-A-7-130560

  In order to form a glasses-shaped winding, it is necessary not only to wind the rectangular wire in a cylindrical shape so that the width direction of the rectangular wire is directed to the center of the winding, but also to wind in the shape of figure 8. Furthermore, after winding into figure 8, it must be wound again into a cylinder. This complicates the winding manufacturing process and increases manufacturing costs. In addition, when winding in the shape of figure 8, an excessive load acts on the flat wire, and there is a possibility that the insulation coating of the flat wire is damaged. If the insulation coating is damaged, it is difficult to ensure sufficient electrical insulation between the windings and other metal parts. In the case of a large current noise filter, there is an extremely high demand for ensuring electrical insulation from the viewpoint of handling large currents.

  Accordingly, the present invention provides a large current noise filter that can easily manufacture a coil and can reduce the manufacturing cost, and can sufficiently ensure electrical insulation without damaging a flat wire during manufacturing. It is another object of the present invention to provide a coil manufacturing method.

  The large current noise filter according to the present invention is formed by edgewise winding a rectangular wire and a core having a base, a middle leg and an outer leg extending in the same direction from the base, and a side surface of the middle leg. A plurality of coils each having a coil portion formed in conformity with each other and a lead portion extending from each end portion of the coil portion, and a plurality of terminal portions each connected to a corresponding lead portion of the plurality of coils. The plurality of coils are juxtaposed in the direction in which the middle leg portion extends in a state where the coil portion is inserted through the middle leg portion, and in the cross section perpendicular to the direction in which the middle leg portion and the outer leg portion extend, Has an oval shape, and the cross-sectional area of the middle leg portion is larger than the cross-sectional area of the outer leg portion.

  In the high-current noise filter according to the present invention, since the coil is formed by edgewise winding a rectangular wire, the coil can be manufactured easily and at low cost. Further, when forming the coil, the step of winding in the shape of figure 8 is not required, so that an excessive load is not applied to the rectangular wire. Therefore, it is possible to prevent the insulation coating of the flat wire from being damaged, and it is possible to sufficiently ensure electrical insulation.

  By the way, in the large current noise filter described in Japanese Patent Application Laid-Open No. 7-130560, the coil is formed into a spectacle-shaped winding, and the coil portion having a cylindrical shape is divided to increase the inductance of the coil. In contrast, in the present invention, the coil portion has an oval shape in a cross section perpendicular to the direction in which the middle leg portion and the outer leg portion extend, and the cross-sectional area thereof is larger than the cross-sectional area of the outer leg portion. It is made into the shape along the side of a leg part. Thereby, the inner cross-sectional shape of the coil portion becomes an oval corresponding to the cross-sectional shape of the middle leg portion, and the coil portion has a relatively large inner cross-sectional area. As a result, the coil included in the high-current noise filter according to the present invention can obtain an inductance equivalent to that of the glasses-shaped winding.

  The coil manufacturing method according to the present invention is a method of manufacturing a coil by edgewise winding a flat wire along the outer peripheral surface of the winding shaft portion, and a part of the outer peripheral surface of the winding shaft portion is A notch is provided, and a gripping step for gripping the flat wire between the gripping member and the notch, and the winding shaft is rotated while the flat wire is gripped, and the winding shaft is rotated by a predetermined angle. And a winding step of pressing the flat wire against the notch with the gripping member.

  In the method for manufacturing a coil according to the present invention, the rectangular wire is wound around the winding shaft portion by rotating the winding shaft portion while holding the flat wire. At this time, since the edgewise winding is used, the manufacturing is easy and the manufacturing cost can be reduced. Further, since the step of winding in the shape of figure 8 is unnecessary, damage to the insulation coating of the rectangular wire due to an excessive load can be prevented in advance, and sufficient electrical insulation can be ensured. Each time the winding shaft rotates by a predetermined angle, the gripping member presses the flat wire against the notch, so that the flat wire spring back that can occur during winding can be reliably suppressed. As a result, a coil without winding looseness can be manufactured.

  The winding shaft portion includes a first rotating member having a first shaft and a second rotating member arranged in parallel with the first rotating member and having a second shaft, and the notch portion is a second member. In the winding process, the winding shaft portion is rotated by 1/2 turn around the first axis so that the flat wire is wound along the outer peripheral surface of the winding shaft portion. Thereafter, the first step of pressing the flat wire against the notch with the gripping member, and the winding shaft portion further about the second shaft so that the flat wire is further wound along the outer peripheral surface of the winding shaft portion. It is preferable to have a second step of rotating the flat wire against the notch portion again with the gripping member after being rotated twice.

  Thus, since the winding shaft portion is rotated using two shafts, for example, even when the cross section of the winding shaft portion has an oval shape instead of a perfect circle, the winding shaft portion is smoothly rotated. Can be made. As a result, the flat wire can be wound smoothly. Since the flat wire is pressed against the notch each time the winding shaft portion is rotated by half a turn, the spring back of the flat wire can be more reliably suppressed.

  ADVANTAGE OF THE INVENTION According to this invention, a manufacturing cost can be reduced and the manufacturing method of a large current noise filter and a coil which does not damage a flat wire at the time of manufacture can be provided.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description, the same reference numerals are used for the same elements or elements having the same function, and redundant description is omitted.

  The large current noise filter 1 according to the present embodiment is for removing noise generated inside an electronic device and blocking noise entering from the outside of the electronic device. More specifically, the large current noise filter according to the present embodiment is a noise filter interposed in a power supply line that connects a computer and a three-phase AC power supply. Hereinafter, the configuration of the large current noise filter 1 according to the present embodiment will be described with reference to the drawings. FIG. 1 is a perspective view showing a large current noise filter according to the present embodiment. FIG. 2 is a perspective view showing a main body included in the large current noise filter according to the present embodiment. FIG. 3A is a side view showing a main body included in the large current noise filter according to the present embodiment, and FIG. 3B is a cross-sectional view taken along line IIIb-IIIb in FIG. FIG. 4 is a perspective view showing a core and a coil included in the large current noise filter according to the present embodiment. 5A and 5B are side views showing core components of the core included in the high-current noise filter according to the present embodiment. Fig.6 (a) is a side view which shows the partition plate contained in the high-current noise filter based on this embodiment, FIG.6 (b) is sectional drawing along the VIb-VIb line | wire of (a). . Fig.7 (a) is a side view which shows the core holder contained in the high current noise filter concerning this embodiment, and FIG.7 (b) is sectional drawing along the VIIb-VIIb line | wire of (a).

  As shown in FIG. 1, the high-current noise filter 1 has a box shape and includes a filter body 10 and a cover 80. The cover 80 is for protecting the filter main body 10, and a terminal block 20 of the filter main body 10 described later is exposed from the side surface of the cover 80. The cover 80 is provided with a screw hole 82 for attaching to the filter body 10.

  As shown in FIG. 2, the filter main body 10 includes a base 12, a pair of terminal blocks 20, a pair of circuit units 30, a core 40, a pair of core holders 50, two partition plates 60, 3 And two coils 70.

  The base 12 is a rectangular metal plate whose upper and lower surfaces are horizontal. In the following description, the long side direction of the base 12 is defined as the X-axis direction, the short side direction of the base 12 is defined as the Y-axis direction, and the direction orthogonal to the X-axis direction and the Y-axis direction is defined as the Z-axis direction. Side walls 14 extending in the Z-axis direction are provided on the side surfaces of the base 12 that face each other along the Y-axis direction. A screw hole 28 for screwing the cover 80 is formed in the side wall 14.

  As shown in FIG. 3, terminal blocks 20 are provided at both ends of the upper surface of the base 12 facing each other along the X-axis direction. Three terminal portions 21 are arranged on the upper surface of the terminal block 20 along the Y-axis direction, and the three terminal portions 21 are partitioned by ribs 24. The terminal portion 21 has a bolt 22 and a conductive plate 26. The conductive plate 26 is fixed to the upper surface of the terminal block 20 with bolts 22 together with a lead-out portion 74 of a coil 70 described later. Next to one of the terminal blocks 20, a terminal block 25 for the ground terminal portion is provided.

  A core 40 is arranged between the pair of terminal blocks 20 on the upper surface of the base 12. The core 40 is supported by a core holder 50 at both ends facing each other along the Y-axis direction. The core 40 is a closed magnetic circuit core. More specifically, the core 40 is obtained by connecting two core members 42 made of a magnetic material (for example, ferrite or the like), and the core member 42 has a substantially U shape. As shown in FIGS. 4 and 5, each core member 42 has a base portion 44, a middle leg portion 46, and an outer leg portion 48. The middle leg 46 and the outer leg 48 extend from the base 44 in the same direction, that is, in the Y-axis direction.

  The middle leg portion 46 is a portion through which a coil 70 described later is inserted. As shown in FIG. 5, the middle leg portion 46 has a substantially oval shape in a cross section perpendicular to the extending direction of the middle leg portion 46 and the outer leg portion 48, that is, the Y-axis direction. By making the middle leg portion 46 without a corner, the coil 70 can be smoothly inserted. In the cross section described above, the outer leg portion 48 has a substantially rectangular shape. By making the outer leg portion 48 substantially rectangular, it is possible to increase the cross-sectional area of the outer leg portion 48 as compared to the case of making it substantially circular, and as a result, the characteristics of the core 40 as a closed magnetic circuit are further improved. It can be good.

  Further, in this cross section, the cross-sectional area of the middle leg portion 46 is larger than the cross-sectional area of the outer leg portion 48 and is about twice as large. More specifically, as shown in FIG. 5, the length L1 in the X-axis direction of the middle leg portion 46 is about 56 mm, and the length L2 in the Z-axis direction is about 32 mm. Both the length L3 in the X-axis direction and the length L4 in the Z-axis direction of the outer leg portion 48 are about 30 mm.

  In the X-axis direction, the distance L6 between the outer leg portion 48 and the middle leg portion 46 is slightly larger than the width of the flat wire 71. More specifically, when the width of the flat wire 71 is about 14 mm, the distance L6 between the middle leg portion 46 and the outer leg portion 48 is about 20 mm. For example, in a high-current noise filter using glasses-shaped windings, it is necessary to separate the legs from each other to such an extent that two rectangular wires can pass. This is because the winding portion of the eyeglass-shaped winding is inserted into each of the two legs of the closed magnetic circuit core. In the large current noise filter 1 of the present embodiment, the coil 70 is inserted only through the middle leg portion 46, so that a single rectangular wire can pass between the outer leg portion 48 and the middle leg portion 46. Good. Thus, since the space between the outer leg portion 48 and the middle leg portion 46 can be narrowed, the cross-sectional area of the middle leg portion 46 can be increased accordingly.

  Each coil 70 is an air-core coil formed by edgewise winding a rectangular wire 71 having an insulating coating. Each coil 70 includes a coil portion 72 that is formed in a cylindrical shape along the side surface (outer peripheral surface) of the middle leg portion 46, and a lead portion 74 that extends from both end portions of the coil portion 72. As shown in FIG. 4, the coils 70 are juxtaposed in the direction in which the middle leg portion 46 extends in a state where the coil portion 72 is inserted through the middle leg portion 46. The flat wire 71 has a rectangular or trapezoidal cross-sectional shape. As shown in FIG. 3B, the inner periphery of the coil portion 72 has an oval shape along the outer periphery of the middle leg portion 46 in a cross section along the X-axis direction. Therefore, the inner cross-sectional shape of the coil portion 72 also has an oval shape. A method for manufacturing such a coil 70 will be described in detail later.

  Each lead-out portion 74 extends toward the terminal block 20 located in the pull-out direction. Each lead-out portion 74 of each coil 70 extends from the coil portion 72 so as to be linear with respect to the axial center direction (Y-axis direction) of the coil portion 72. The leading end portion of the lead-out portion 74 is twisted 90 degrees so that the wide surface faces the Z-axis direction. The leading end portion of the lead-out portion 74 is connected to the conductive plate 26 as a terminal portion of the coil 70 by being bolted together with the conductive plate 26 corresponding to each coil 70.

  As shown in FIG. 2, two partition plates 60 are installed on the core 40 so as to partition each of the three coils 70. As shown in FIG. 6, the partition plate 60 has a first through hole 62 and a second through hole 64. The middle leg portion 46 of the core 40 is inserted into the first through hole 62, and the outer leg portion 48 of the core 40 is inserted into the second through hole 64.

  As shown in FIGS. 2 and 3, core holders 50 are provided at both ends of the core 40 along the Y-axis direction. As shown in FIG. 7, the core holder 50 includes a first through hole 52, a second through hole 54, and a contact wall 56. The middle leg portion 46 of the core 40 is inserted through the first through hole 52, and the outer leg portion 48 is inserted through the second through hole 54. The contact wall 56 is provided between the first through hole 52 and the second through hole 54. The surface 56 a of the contact wall 56 faces the surface 44 a of the base portion 44 between the middle leg portion 46 and the outer leg portion 48.

  The circuit unit 30 includes circuit elements such as capacitors and resistors. The circuit unit 30 is connected to the conductive plate 26 described above, and is electrically connected to the lead-out unit 74 of the coil 70 via the conductive plate 26. 2 and 3, the coil 70 is disposed so that the coil portion 72 is positioned between the lead-out portion 74 and the base 12 when viewed in the Z-axis direction. As a result, a space S corresponding to the width of the coil portion 72 in the Z-axis direction is formed between the lead-out portion 74 and the base 12. The circuit unit 30 is arranged in the space S using the space S, and the high-current noise filter 1 is reduced in size.

  Here, a method for manufacturing the coil 70 will be described. 8-13 is a figure which shows the manufacturing method of the coil 70. As shown in FIG. 8A to 13A are top views showing a part of a manufacturing apparatus used when manufacturing the coil 70, and FIG. 8B is a side view showing a part of the manufacturing apparatus. This manufacturing apparatus manufactures an air-core coil wound edgewise by shifting the winding shaft portion 102 in the axial direction while winding the flat wire 71 around the winding shaft portion 102 of the manufacturing apparatus.

  The manufacturing apparatus includes a wire guide 101, a winding shaft portion 102, and a clamp (gripping member) 110. The wire guide 101 is a portion that guides a flat wire 71 supplied from a bobbin (not shown) to the winding shaft portion 102.

  The winding shaft portion 102 is a portion that winds up the flat wire 71 guided by the wire guide 101. The winding shaft portion 102 includes a first rotating member 104 having a first shaft 103, a second rotating member 106 having a second shaft 105, and a main rotating member 107. The 1st rotation member 104 and the 2nd rotation member 106 are exhibiting the shape which notched the side surface of the cylinder. The first rotating member 104 and the second rotating member 106 are arranged in parallel with the notch surfaces 104a and 106a facing each other. The second rotating member 106 is provided with a notch 108. A clamp 110 is provided below the notch 108 of the second rotating member 106. The clamp 110 is a portion that clamps the flat wire 71 along the winding shaft portion 102. The flat wire 71 is gripped between the clamp 110 and the notch 108. The clamp 110 rotates together with the winding shaft portion 102.

  The main rotating member 107 is connected to one of the first rotating member 104 and the second rotating member 106. Of the first rotating member 104 and the second rotating member 106, the winding shaft portion 102 rotates around the axis connected to the main rotating member 107.

  The coil 70 is manufactured as follows. First, the rectangular wire 71 drawn out from the bobbin of the manufacturing apparatus is guided by the wire guide 101 so that the narrower surface of the rectangular wire 71 is along the lower surface of the winding shaft portion 102. A portion of the guided flat wire 71 located below the notch 108 is clamped by the clamp 110. As shown in FIG. 8, the main rotating member 107 is connected to the first rotating member 104 and the rectangular wire 71 is clamped by the clamp 110, and the winding shaft portion 102 is moved around the first shaft 103. Rotate 90 degrees in direction A. By rotating in the arrow A direction, the flat wire 71 is wound along the outer periphery of the winding shaft portion 102.

  After rotating 90 degrees, the winding shaft portion 102 is further rotated 90 degrees in the direction of arrow A as shown in FIG. That is, the winding shaft part 102 is rotated 1/2 turn from the state of FIG. After the rotation, as shown in FIG. 10, the flat wire 71 is pressed in the direction of the notch 108 by the clamp 110. As a result, the flat wire 71 is pressed against the notch 108, and the spring back of the flat wire 71 can be suppressed.

  After pressing the flat wire 71, the clamp 110 is returned to the original position as shown in FIG. At the same time, as shown in FIG. 11A, the main rotating member 107 is moved, and the connection destination is changed from the first rotating member 104 to the second rotating member 106. Then, in a state where the flat wire 71 is clamped by the clamp 110, this time, the winding shaft portion 102 is rotated 90 degrees in the arrow A direction around the second axis.

  After rotating 90 degrees, the winding shaft portion 102 is further rotated 90 degrees in the direction of arrow A as shown in FIG. That is, the winding shaft portion 102 is further rotated by 1/2 turn from the state shown in FIG. After the rotation, as shown in FIG. 13, the flat wire 71 is pressed toward the cutout portion 108 by the clamp 110. As a result, the flat wire 71 is pressed against the notch 108 again, and the spring back of the flat wire 71 can be more reliably suppressed. After pressing the flat wire 71, the clamp 110 is returned to the original position. At the same time, the main rotating member 107 is moved to connect the main rotating member 107 to the first rotating member 104. Thereafter, similarly, by rotating the winding shaft portion 102 a predetermined number of times, the flat wire 71 is wound edgewise and the coil 70 without winding looseness is manufactured.

  As described above, in the present embodiment, since the coil 70 is formed by edgewise winding the rectangular wire 71, the coil 70 can be manufactured easily and at low cost. Further, when the coil 70 is formed, the step of winding in the shape of figure 8 is not required, so that an excessive load is not applied to the flat wire 71. Therefore, it is possible to prevent the insulation coating of the flat wire 71 from being damaged, and to sufficiently ensure electrical insulation.

  In this embodiment, the coil part has an oval shape in a cross section perpendicular to the direction in which the middle leg part 46 and the outer leg part 48 extend, and the middle leg has a larger cross-sectional area than the cross-sectional area of the outer leg part 48. The shape is formed along the side surface (outer peripheral surface) of the portion 46. Thereby, the inner cross-sectional shape of the coil portion becomes an oval shape corresponding to the cross-sectional shape of the middle leg portion 46, and the coil portion has a relatively large inner cross-sectional area. As a result, the coil 70 can obtain an inductance equivalent to that of the eyeglass-shaped winding.

It is a perspective view which shows the high current noise filter which concerns on this embodiment. It is a perspective view which shows the main-body part contained in the large current noise filter which concerns on this embodiment. It is the side view and sectional drawing which show the main body contained in the high current noise filter which concerns on this embodiment. It is a perspective view which shows the core and coil which are included in the high current noise filter which concerns on this embodiment. It is a side view which shows the core contained in the high current noise filter which concerns on this embodiment. It is the side view and sectional drawing which show the partition plate contained in the high current noise filter which concerns on this embodiment. It is the side view and sectional drawing which show the core holder contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment. It is a figure which shows the manufacturing method of the coil contained in the high current noise filter which concerns on this embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... High current noise filter, 10 ... Main body, 12 ... Base, 21 ... Terminal part, 40 ... Core, 44 ... Base part, 46 ... Middle leg part, 48 ... Outer leg part, 70 ... Coil, 71 ... Flat wire, 102 ... winding shaft part, 104 ... first rotating member, 106 ... second rotating member, 108 ... notch, 110 ... clamp.

Claims (3)

A core having a base, and a middle leg and an outer leg extending in the same direction from the base;
A plurality of coils each formed by edgewise winding a rectangular wire, and having a coil portion formed in a cylindrical shape along the side surface of the middle leg portion, and a lead portion extending from both end portions of the coil portion, ,
A plurality of terminal portions each connected to the corresponding drawing portion of the plurality of coils,
The plurality of coils are juxtaposed in a direction in which the middle leg portion extends in a state where the coil portion is inserted through the middle leg portion,
In a cross section perpendicular to the direction in which the middle leg portion and the outer leg portion extend, the middle leg portion has an oval shape, and the cross-sectional area of the middle leg portion is larger than the cross-sectional area of the outer leg portion. A large current noise filter characterized by that. A method of manufacturing a coil by edgewise winding a flat wire along the outer peripheral surface of a winding shaft part,
A part of the outer peripheral surface of the winding shaft part is provided with a notch,
A gripping step of gripping the flat wire between the gripping member and the notch,
The winding step of rotating the winding shaft portion in a state of gripping the flat wire, and pressing the flat wire against the notch portion with the gripping member each time the winding shaft portion rotates by a predetermined angle;
A method for manufacturing a coil, comprising: The winding shaft portion includes a first rotating member having a first shaft, and a second rotating member arranged in parallel with the first rotating member and having a second shaft,
The notch is provided in the second rotating member;
The winding step
After rotating the winding shaft part by 1/2 turn around the first axis so that the flat wire is wound along the outer peripheral surface of the winding shaft part, the rectangular wire is moved by the gripping member. A first step of pressing against the notch,
The winding shaft portion is further rotated by 1/2 turn around the second shaft so that the flat wire is further wound along the outer peripheral surface of the winding shaft portion, and then the flat member is rotated by the gripping member. A second step of pressing the line against the notch again;
The method for manufacturing a coil according to claim 2, comprising:

Images