JP2000245092A - Concentrated wound coil and winding apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a coil compact by improving the winding method of the coil and to prevent disorder in aligned state of a coil wire in a coil manufacturing process. SOLUTION: In this concentrate winding coil, a coil wire is wound so as to form a plurality of layers, and the coil wire is wound so as to form a row in every layer. At this time, a layer shift part U1 in which the coil wire is shifted from one layer to a next layer and a row shift part C2 in which the coil wire is shifted to a neighboring row inside the next layer are deviated to separate positions in the circumferential direction of the coil. Due to a layer shift and a row shift, the inclination and the floating of the coil wire are divided, and it is possible to prevent a lump from being generated in the end- face of the coil. In addition, it is suitable that the coil wire whose layer is shifted is supported by a plate or the like so as to suppress the inclination of the wire. In another way, row shift parts are arranged in different positions in every layer. In addition, in another way, a layer shift part and a row shirt part are arranged in the corner part of the coil.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concentrated winding coil and, more particularly, to a technique for improving the winding of a coil wire to make the coil compact. According to the present invention, disturbance of the arrangement of the coil wires in the manufacturing process is prevented.

[0002]

2. Description of the Related Art A concentrated winding coil is a coil wound around one tooth of a motor.
This coil is disposed over one slot and is disclosed, for example, in Japanese Patent Application Laid-Open No. 9-308142.

In order to meet the demand for improved motor performance,
An aligned type concentrated winding coil is effective. The coil wires are wound in parallel so as to be aligned, and one winding layer is formed. At the end of the winding layer, the coil wire is transferred to the next layer, and the coil wire is wound so that the row advances in the opposite direction. The alignment winding is repeated to form a plurality of rows and a plurality of layers of coils. And it is preferable to use a rectangular wire as a coil wire. The rectangular wire has a substantially rectangular cross-sectional shape, and the space factor of the motor can be improved by aligning the rectangular wires without gaps. The space factor is the ratio of the occupied area of the coil wire to the cross-sectional area of the slot, and the motor performance can be improved by increasing the space factor.

[0004]

In a conventional relatively simple type of coil, there is no problem even if the shape of the portion where the coil wires move from row to row and from layer to layer is not particularly taken into consideration. Was wrapped around.
However, it has been found that when an alignment type coil is manufactured by the same method, a bump is formed on both end faces of the coil, and this bump may cause a misalignment.

[0005] Referring to FIGS. 1 to 7, a description will be given of the result of the present inventor's analysis of the cause of the above-mentioned formation of an aneurysm.

Here, a case of manufacturing a coil having a trapezoidal cross section shown in FIG. 1 will be described. For identification, the odd-numbered coil wires are provided with patterns. This coil is formed by winding a coil wire around a bobbin, and the bobbin is rectangular when viewed from the direction of its rotation axis (winding axis). Further, the winding frame has flanges at both ends for defining a coil end surface.

FIG. 2 shows a winding start state of the second layer. In the first layer, the coil wires are switched from row to row in a S-shape at the same position every round (row switching section). The first row of the second layer is wound over the last row of the first layer, which starts the second layer. Hereinafter, a portion where the coil wire runs up from layer to layer on the coil end surface is referred to as a layer change portion.

FIG. 3 shows the end state of the winding of the second layer. Rearrangement is performed at the place where the first row of the second layer goes around,
The second row of the second layer starts. Thereafter, the line change is repeated at the same position every round. As a result, the first row of S-shaped lines and the second
The S-shape changing of the layers intersects, and the intersections are arranged substantially linearly in the winding axis direction.

FIG. 4 shows a cross-sectional shape of each part of the layer change part of FIG. Fig. 2 shows the lower coil wire that serves as the basis for changing layers.
As shown in (1), the coil wire is inclined and twisted in the layer change portion due to the effect of running obliquely. The inclination of the coil wire starts near the cross section AA. As the section proceeds to the cross section BB, the coil wire rises and the torsional inclination increases. Then, the twist of the coil wire remains near the cross section CC.

Next, FIG. 5 shows a cross-sectional shape of each part in FIG. 3, particularly, a row switching portion of the second layer from the first row to the second row. FIG. 5A illustrates the locus of a coil wire that intersects with a coil wire of a layer change portion one revolution before and switches rows. In the process of changing the row, the coil wire twists and tilts in the opposite direction to the layer changing portion.
In this portion, the coil wire rises most greatly, and a coil end surface aneurism is generated. The torsion of the coil wire remains even in the cross section bb in FIG.

Further, as shown in FIG. 6, when the third layer and the fourth layer are wound, the torsion of the coil wire is accumulated, and as a result, the alignment state is disturbed and the coil wire slides down. It is possible.

FIG. 7 is a view of the bump on the coil end face as viewed from the direction of the winding axis. Since the layer change portion to the second layer and the S-shaped change portion in the second layer are at the same position, when the coil wire draws an S shape, it is pushed up by the raised coil wire of the layer change portion. . The inclination and the float of the line of the layer change part and the line change part are superimposed, and the bump becomes large as shown in the figure.

As described above, in the manufacturing process of the aligned concentrated winding coil, a bump may be generated near the coil end face, and the main causes thereof are the inclination of the coil wire in the row change portion and the layer change portion and the floating. On the rise.

As shown in the above example, in the concentrated winding coil, portions such as the layer changing portion and the column changing portion disturb the arrangement of the coil wires and cause the coil outer shape to be enlarged. It is considered that the size of the coil can be reduced by devising the positions of these portions. Then, the size of the motor can be reduced, the output per the same size can be increased, and the motor performance can be improved.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a concentrated winding coil that can be prevented from increasing in coil size by improving the winding method of the coil and can be made compact. It is an object of the present invention to provide a concentrated winding coil capable of suppressing coil end face bumps and associated arrangement disorder, and an apparatus for manufacturing the same.

[0016]

(1) In order to achieve the above object, according to the present invention, a coil wire is wound so as to form a plurality of layers, and a coil wire is wound so as to form a row in each layer. In the concentrated winding coil, a layer change part where the coil wire moves from one layer to the next layer and a line change part where the coil wire moves to the next row in the next layer are separated from each other in the coil circumferential direction. It is characterized by having. For example, a row change section in the second layer is provided at a position shifted in the coil circumferential direction with respect to a layer change section to the second layer. Therefore, the formation of bumps due to the overlapping action of the layer changing section and the row changing section can be suppressed, and the arrangement disorder can be prevented.

As described above, according to the present invention, by focusing on the factor parts that generate the coil arrangement disorder, ie, the row change part and the layer change part, by shifting these factor parts, the accumulation of disorder such as a bump can be achieved. The number of coils is reduced, thereby making the coil more compact.

[0018] The preferred winding manufacturing apparatus of the present invention includes a row forming apparatus, and the row forming apparatus is provided in the next layer with respect to a layer changing section where a coil wire moves from one layer to the next layer. Then, the coil wire is formed into a column-changing S-shape at the column-changing position such that the column-changing portion where the coil wire moves to the next row is at a different position shifted in the coil circumferential direction. The row changing device forms the coil wire into an S-shape at an appropriate place before the coil wire reaches the layer change portion (press forming or the like), for example. Thereby, the layer change section and the row change section can be effectively separated.

[0019] Preferably, the winding manufacturing apparatus further includes a tilt preventing device for preventing the tilt of the coil wire by supporting the coil wire portion going up to the next layer by the layer changing section. Since the coil wire runs obliquely in the layer change portion, a gap is formed below the coil wire, and this gap also causes the coil wire to twist. However, according to the present invention, by supporting the coil wire using the gap, the twist of the coil wire can be suppressed, and the bump can be further reduced. For example, it is preferable to insert a member having a shape that fills the gap of the layer change portion into the gap portion and support the coil wire from below.

Preferably, the winding manufacturing apparatus has a coil wire floating prevention device, and the floating prevention device prevents the coil wire from floating by pressing down the layer change portion from the outer peripheral side. For example, a holding member corresponding to a desired layer change slope shape is provided. According to this aspect, it is possible to further reduce the bumps on the coil end face portion and obtain a better alignment state.

(2) Another aspect of the present invention is a concentrated winding coil in which a coil wire is wound so as to form a plurality of layers, and a coil wire is wound in each layer so as to form a row. It is characterized in that a row switching portion for shifting from a row to an adjacent row is provided at another position shifted in the coil circumferential direction in each layer.

According to the present invention, since the coil wire switching portions are formed at different positions in each layer, the accumulation of the coil wire disturbance due to the row switching portions is reduced. Since the column rearranging portions of all layers are located at the same location, it is possible to prevent the column rearranging disturbance from being accumulated and the overall shape of the coil from being significantly disturbed. Therefore, the coil can be made compact.

(3) Another aspect of the present invention is a concentrated winding coil in which a coil wire is wound so as to form a plurality of layers, and a coil wire is wound in each layer so as to form a row. A layer change portion for shifting from the first layer to the next layer is formed at a corner of the coil. Preferably, a column switching portion that transitions from one row to the next row of the coil wire is also formed at the corner of the coil.

According to the present invention, since the layer change section and the row change section are arranged in the useless space of the coil corner, the coil shape is prevented from being enlarged due to the disorder of the arrangement in other portions, and as a result, the entire coil is compact. Can be achieved. Therefore, even in this mode, it is possible to make the coil compact by devising the winding method.

As described above, according to the present invention, the arrangement of the coil wires is reduced due to the contrivance of the winding method of the coil, and the coil can be made compact. As a result, the size of the motor can be reduced. The output per unit size can be increased, and the motor performance can be improved.

[0026]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, a concentrated winding coil and winding manufacturing apparatus according to a preferred embodiment (embodiment) of the present invention will be described with reference to the drawings.

FIG. 8 is a side view (a) and a plan view (b) of the winding manufacturing apparatus. A rectangular coil wire (flat wire) 3 is wound around the rotatable wire bobbin 1.
The flat wire 3 drawn from the wire bobbin 1 is guided by a guide roller 5 and reaches a bobbin 7. It is also preferable that a wire having a round cross section is wound around the wire bobbin 1, a rolling roller is provided between the wire bobbin 1 and the guide roller 5, and the cross-sectional shape of the coil wire is formed from a circle to a square.

The winding frame 7 is gripped and rotated by a spindle device (not shown). The flat wire 3 is pulled out of the wire bobbin 1 by the rotation of the bobbin 7 and wound up around the bobbin 7, whereby a coil according to the shape of the bobbin 7 is formed. The flat wire 3 is guided in an appropriate direction by the axial movement of the guide roller 5,
The flat wire 3 is aligned on the bobbin 7 to form a plurality of layers.

Here, in order to increase the motor space factor,
It is preferable that the coil is configured as follows, instead of forming a spiral in which the coil wires are gradually rearranged over the entire circumference.

Referring to FIG. 9, when the coil is assembled to the motor, the slot mounting portions P1 and P2 corresponding to the long sides of the rectangular coil are accommodated in the status lot, and the coil ends Q1 and Q2 on the short side are separated from the stator end face. Assume that it protrudes in a loop. At the slot mounting portions P1, P2 and one of the coil ends Q2, the coil wires are arranged parallel to each other in a direction perpendicular to the winding axis X, and at the other coil end Q1, the coil wires are rearranged and layered. Start where you change. Since the layer change part of each layer occurs at the line change part of the previous layer, the line change at each layer occurs on the coil circumference by the separation distance between the layer change part and the line change part in the winding frame rotation direction every time the layer changes. They will move. In other words, the rearrangement and the layer change portion are distributed over the entire circumference of the coil, and a coil winding cross section having a high filling rate without end face bumps can be obtained as a whole coil.

In order to realize the above-described coil configuration, the guide roller 5 is controlled according to the rotation of the bobbin 7. That is, the slot mounting portions P1, P2 and the coil end Q2
When the coil wire is wound around the guide roller 5, the guide roller 5 stops. When the coil wire is wound around the other coil end Q1, the guide roller 5 moves by one pitch,
Realize column sorting. During the winding of the last row of the layer and the first row of the next layer, that is, during two rotations of the bobbin, the guide roller 5
Is stationary, so that the layer change is performed at the coil end Q1. Thereafter, by roller control according to the winding frame phase and the like, the roller is moved at an appropriate timing in accordance with the winding at the current row change position.

Returning to FIG. 8, the winding frame 7 has flanges 9 at both ends in the rotation axis direction, and the flanges 9 define both ends of the coil.

In the vicinity of the flanges 9 at both ends of the bobbin 7, row change devices 11 are provided. The rearrangement molding device 11
It has S-shaped forming claws 13 and 15 for forming an S-shaped replacement of coil wires by press forming. Molding device 1
Reference numeral 1 denotes a forming claw 13, 1 by an actuator (not shown).
5 is moved to the vicinity of the bobbin 7, and the coil wire being wound is press-formed.

On both sides of the bobbin 7, a layer change preventing device 17 is provided. Here, the term “inclination” refers to the twisting and rising of the line at the layer change portion shown in FIG. The tilt prevention device 17 has a tilt prevention plate 19 that can be advanced and retracted by an actuator (not shown). The tilt preventing device 17 moves the rod-shaped tilt preventing plate 19 in the winding axis X direction toward the bobbin frame 7.

As shown in the front view of FIG. 8B, a device 21 for preventing the line from being lifted immediately after winding by the coil winding tension is provided near the winding frame 7. The lifting prevention device 21 has a frame-shaped lifting prevention plate 23, and the plate 23 can be moved by an actuator (not shown) and fitted to the outside of the bobbin 7.

Next, referring to FIG.
The function of will be described. FIG. 10 shows the winding start portion of the second layer as in FIG. However, the left half of the bobbin is omitted in FIG. In the first layer shown with a pattern, the line is switched every time at a fixed position C1. In the layer change section U1, the coil wire runs up onto the S-shaped section to the last row of the first layer.

As a feature of this embodiment, after a layer change from a certain layer to the next layer, the next layer is changed at a location circumferentially distant from the layer change portion. In the example of FIG. 10, the layer switching unit U1 for the second layer and the column switching unit C2 for the second layer are shifted. The amount of displacement between the two portions is set to such an extent that the effects of the present invention described later are obtained, that is, to such an extent that the effects of stratification and rearrangement on the formation of a nodule can be sufficiently separated.

The row change of the second layer at the row change position C2 is realized by a row forming apparatus. When the winding of the second layer starts, the row-replacement molding apparatus starts the S-shaped molding claws 13 and 1.
5 is moved from the retracted position to the illustrated press forming position. The S-shaped forming claws 13 and 15 have opposing forming surfaces corresponding to the S-shaped shape to be formed. The coil wire is sandwiched between the molding surfaces of both claws, and an S-shape suitable for rearrangement is formed on the coil wire. The S-shaped change in the second and subsequent rows of the second layer is similarly performed in the change section C2 without performing press forming using the forming claws 13 and 15.

To explain a specific example of the above-mentioned forming process, after the winding of the first row of the second layer, the starting portion of the second row of the second layer is:
Once wound on top of the first row of the second layer. At this time,
The guide roller 5 temporarily stops moving in the axial direction. Then, press forming is performed at the position C2 by the forming claws 13 and 15, and at the same time, the guide roller 5
Move in the winding advance direction. Thereafter, if the guide roller 5 moves by one pitch every time the winding frame 7 makes one rotation, the second layer is switched at the same position C2 every time.

Assuming that the winding of the second layer is performed at random, without performing the above-described row changing molding, the row changing of the second layer is performed at the same position (U1) as the layer changing section. Would. On the other hand, in the present embodiment, the S-shaped claw 13, 1
5 is used to forcibly create the S-shaped change at the desired position C2, and the conscious position of the change is controlled. By setting the line changing portion C2 a predetermined distance before the layer changing portion, both portions are isolated.

Here, if the layer change section and the next row change section are located at the same position, as described with reference to FIG. Swell. On the other hand, in the present embodiment, the layer change section and the row change section are provided at positions shifted as described above. The S-shape of the line change is drawn at a position where the coil wire passes over or does not cross over the coil wire of the rising portion. Therefore, it is possible to reduce the size of the bump formed on the outer periphery of the coil. As a result, it is possible to prevent the coil wires from being out of alignment due to the bump.

Although the layer change portion from the first layer to the second layer has been mainly described here, the same configuration is adopted for other portions.

Next, referring to FIG. 11, the function of the layer change preventing device for preventing the coil wire from being tilted at the layer changing portion will be described. FIG. 11 shows the beginning of the second layer as in FIG. The layer change position and the line change position are shifted by the line change S-shaped molding.

In the layer change portion, since the coil wire runs obliquely to the second layer, a cavity (layer change gap) is generated between the coil wire and the bobbin. As shown in FIG. 11B, the shape of the layer change gap is a substantially wedge-shaped triangle when viewed from the winding axis direction. However, FIG. 11B shows a gap shape on the assumption that no twisting of the coil wire has occurred. Actually, the coil wire tends to enter the layer change gap and tilt by its own elastic force or the like.

FIG. 1 shows a layer change prevention device according to this embodiment.
1 (b) is provided with a line inclination preventing plate 19 having a cross-sectional shape corresponding to the ideal layer change gap. This line inclination prevention plate 19
Is inserted into a layer change gap from a through hole of the same shape provided in the flange 9 of the winding frame 7.

The timing for inserting the line inclination preventing plate 19 is preferably before the winding of the layer change portion. FIG.
In the example of the second layer in (a), the line inclination preventing plate 19 is inserted after the last row of the first layer is rearranged. At the point where the layer change portion is wound around the second layer, the line inclination preventing plate 19 has already been inserted.

FIG. 11C shows a state in which the layer is switched to the second layer after the line inclination preventing plate 19 is inserted. In FIG. 11D, the coil wires of the second layer and the third layer are further wound, and the line inclination preventing plate 19 for the fourth layer is wound.
Are inserted, and the fourth layer is being wound.

As described above, the line inclination preventing device has a plurality of line inclination preventing plates 19 used for different winding layers, and each plate is inserted into a corresponding layer change gap. These tilt prevention plates 19 are held until the winding of the coil is completed. Before the completed coil is removed from the bobbin, the inclination preventing plate 19 is removed by an actuator (not shown).

In the case where a trapezoidal coil as shown in FIG. 1 is formed, the run-up is shifted in the column direction at the step portion of the pyramid, so that it is not necessary to insert the line inclination preventing plate. However, it is preferable to insert the line inclination preventing plate 19 in the parallel portion before the step portion starts. From this point of view, in the present embodiment, the line inclination preventing devices are arranged on both sides of the winding frame 7.

As described above, in the present embodiment,
The line inclination preventing member is inserted into the gap between the layer changing sections, and the coil wire of the layer changing section is lowered (inside the coil) by the inclination preventing member.
Supported from. Then, the coil wire is restrained so as not to be deformed into the gap between layers. Therefore, the line inclination of the layer change portion and the accompanying floating are prevented, and the disorder of the alignment state of the coil wires is reduced. In particular, as described above, the influence of the deformation of the row changing portion and the effect of the deformation of the layer changing portion are dispersed, and the floating of the layer changing portion and the surroundings is reduced, so that the coil wire bump can be further reduced. it can.

Next, with reference to FIGS. 12 and 13, the function of the floating prevention device at the layer change portion will be described.

FIG. 12A shows a state immediately after the layer change portion is wound around the second layer. If the rotation of the winding frame 7 proceeds as it is, there is a possibility that the coil wire will rise in a relatively wide range in the layer change portion and its peripheral portion due to the coil winding tension generated in the coil wire.

The floating prevention device is for preventing the floating of the coil wire, and has a frame type floating prevention plate 23 shown in FIG. Floating prevention plate 23
Is made of a thick plate capable of obtaining a sufficiently high rigidity that does not deform even when the spring force of the coil wire acts, and has a shape surrounding three sides of the winding frame 7.

The lifting prevention plate 23 is provided with a recess 25 into which the winding frame 7 is fitted together with the coil being wound. The support protrusions 27 and 29 and the lifting presser protrusion 31 project from three directions toward the inside of the recess 25. The holding protrusion 31 has a holding surface 31a corresponding to a desired shape around the layer change part and the front and rear. The support protrusion 27 is provided at a position facing the protrusion 31 with the winding frame 7 interposed therebetween. The support protrusion 29 is provided on a side perpendicular to the side on which the protrusion 31 is provided. In addition, the area A where the floating holding protrusion 31 is provided is thicker than the other general parts, and the step between the area A and the general part is substantially equal to the width t of the coil wire.

The lifting prevention device is driven by an actuator (not shown) in the direction of the dotted arrow in FIG.
3 is moved and fitted into the bobbin 7. The fitting timing is preferably immediately after winding of the layer change portion as shown in FIG.

FIGS. 13A and 13B show a state in which the floating prevention plate 23 is fitted on the outside of the winding frame 7. FIG.
As shown in FIG. 3B, the support protrusions 27 and 29 are in contact with the coil of the first layer, and the holding protrusion 31 is in contact with the layer change part to the second layer. Further, as shown in FIG. 13A, the general portion of the floating prevention plate 23 is fitted at a position separated from the flange 9 of the winding frame 7 by one coil wire (t). Therefore, the support protrusions 27 and 29 do not hit the flange 9 either. However, since the presser protrusion 31 has a step with a height t between the presser protrusion 31 and the general portion, the presser protrusion 31 contacts the flange 9. Actually, if the lifting prevention plate 23 is pressed toward the flange 9, the arrangement shown in FIGS. 13A and 13B is naturally obtained.

13 (b) to 13 (e), when the winding frame 7 rotates, the coil wire tends to float at the layer change portion and its periphery due to the tension force applied to the coil wire.
However, the lifting prevention plate 23 is supported by the supporting protrusions 27 and 29, and the pressing protrusion 31 presses the layer change portion. As a result, the coil wire is prevented from floating, and the coil wire maintains a shape corresponding to the pressing surface 31a of the protrusion 31.

When the bobbin is rotated to the position shown in FIG. 13 (e), the lifting prevention plate 23 is removed from the bobbin 7 by an actuator (not shown) so as not to hinder the subsequent steps, and a predetermined evacuation is performed. Move to position. Thereafter, the S-shape forming with the forming claws described with reference to FIG. 10 is performed.

The above-mentioned floating prevention plate 23 is used only at the coil end where layer change occurs. When a row other than the coil end is wound, the floating prevention plate 23 is held at the retracted position.

Although the description has been given by taking the layer change portion to the second layer, the floating is similarly prevented for other layers. The floating prevention device includes a plurality of floating prevention plates 23 used for different layers. Each plate has the shape of the recess 25 corresponding to the corresponding layer. For example, in the floating prevention plate 23 for the third layer, the concave portion 25 is spread outward by two coil wires as compared with that for the first layer.

As described above, according to the present embodiment, an appropriate predetermined period during the winding of the first row after the layer change,
The layer change part is pressed down from the outer peripheral side. As a result, it is possible to reduce the lifting of the coil wire which causes the formation of the bump on the coil end surface. By using a layer change prevention plate together with the aforementioned S-shaped claw and layer change gap insertion member,
Further, it is possible to make it difficult to form an aneurysm and to effectively prevent the alignment from being broken.

[Second Embodiment] Next, a concentrated winding coil according to a second embodiment will be described. Also in this embodiment, the coil can be made compact by improving the winding method. In order to achieve this object, in the present embodiment, as will be described below, a column switching portion that transitions from one row to the next row is formed at a different position in the coil circumferential direction in each layer.

FIG. 14 shows a concentrated winding coil according to this embodiment. As in the first embodiment, a portion corresponding to the long side of the rectangle is fitted into a slot of the motor stator. The portion corresponding to the short side is a coil end, which is a portion protruding in a loop from the end face of the stator. The rearrangement of the coil wires is performed at one coil end (upper side in FIG. 14).

Now, in the present embodiment,
As shown in FIG. 14, the coil wire column changing units are distributed to the left and right. In the winding of a certain layer, the column is switched at the right column switching position, in the next layer, the column is switched at the left column switching position, and in the next layer, the column is switched again at the right column switching position.

Here, FIG. 15 as a comparative reference diagram shows the coil shape when the row change portions of all layers are arranged at the same position (the center of the coil end). The total coil thickness of the general portion is substantially equal to the product of the wire thickness (thickness of one coil wire) and the number of layers. However, the coil thickness A of the coil end is much larger than the general part. This is because the column change units of all layers are at the same location. Disturbances due to column rearrangement are accumulated, and the overall shape of the coil is largely disturbed and enlarged.

On the other hand, in the present invention shown in FIG. 14, the coil thickness B of the coil end portion is smaller than the coil thickness A of FIG. It is considered that this is because the column rearranging portions causing the disturbance of the coil wires are dispersed, and the accumulation of the disturbance is reduced.

As described above, according to the present embodiment, since the row switching portion is formed at a different position in the coil circumferential direction in each layer, the coil can be made compact. In addition,
The arrangement of the column switching units is not limited to the configuration shown in FIG. 14, and it is needless to say that the column switching units can be appropriately changed. The positional shift of the column switching units is also suitably applied to the first embodiment. .

The concentrated winding coil of the present embodiment is also preferably manufactured by using the winding manufacturing apparatus shown in FIG.

[Third Embodiment] Next, a concentrated winding coil according to a third embodiment will be described. Also in this embodiment, the coil can be made compact by improving the winding method. In order to achieve this object, in the present embodiment, as described below, the layer change section and the row change section are formed at the corners of the coil.

FIG. 16 shows a concentrated winding coil according to this embodiment. In the present embodiment, as a feature, the layer change portion and the column change portion of the coil wire (the portion where the coil wire intersects)
Are arranged at the corners of the coil. The coil corner portion is a portion that moves from the slot mounting portion to the coil end, and is a start portion and an end portion of the coil end. The coil corner is
This is a portion where the shape of the coil is bent, and the coil wire bends at this portion. In coil manufacturing, all layers and rows are changed at one coil corner,
Thereby, the layer change part and the line change part are gathered at the corner.

Here, there is a useless space as a coil at the corner of the coil. It is assumed that the coil is assembled in a rectangular parallelepiped storage space as shown by a two-dot chain line m in FIG. At this time, since the coil wire draws a curve (a quarter circle) at the corner of the coil, a relatively large gap is formed outside the coil. In the present embodiment, the useless space corresponding to the gap is filled by coil enlargement caused by the layer change section and the column change section. Therefore, it is possible to prevent the coil shape from expanding outward at the coil end portion. That is, the coil thickness C of the coil end portion in FIG. 16 is significantly smaller than the coil thickness A in FIG. 15, and is substantially equal to the coil thickness of the general portion (= wire thickness × number of layers). equal.

As described above, according to the present embodiment, the layer change section and the row change section are arranged in the useless space at the corner of the coil. As a result, the entire coil can be made compact.

According to the present embodiment, the total length of the coil wire can be shortened by making the coil compact. As a result, the material cost of the coil can be reduced. Further, the resistance at both ends of the coil is reduced, and the energy loss (so-called copper loss) can be reduced. This is the same in the above-described embodiment.

The concentrated winding coil of the present embodiment is also preferably manufactured using the winding manufacturing apparatus shown in FIG.

[Other Embodiments] Next, a description will be given of an improved winding manufacturing apparatus capable of effectively preventing the coil wires from being misaligned at the coil end faces.

FIG. 17 shows a reel 51 of the reel manufacturing apparatus. The winding form (wound portion) 53 of the winding frame 51 is substantially rectangular when viewed from the winding axis X direction. From both sides of the winding form 53,
Chuck portions 55 and 57 project in the winding axis X direction. The chuck portions 55 and 57 are respectively held by a first spindle and a second spindle (not shown) of the double-head spindle device.

A flange 59 is provided between the former 53 and the chuck part 55. The flange 59 has a step of one coil wire between the flange 59 and the former, and functions as a winding reference surface of the first layer. The winding frame 51 has a lead holder 61 projecting from the flange 59, and the coil lead portion at the start of winding is hooked on the holder 61. Further, the bobbin 51
The first end face collapse prevention block 63 is provided on the flange 59.
Having. The block 63 is arranged on the opposite side of the lead holder 61 and protrudes from the flange 59 in a direction perpendicular to the winding axis X.

In the vicinity of the end of the former 53 on the chuck 57 side, a second end face collapse prevention block 65 is detachably provided. The block 65 is orthogonal to the winding axis X,
It penetrates the former 53, protrudes from both upper and lower sides of the former 53, and is fixed to the former 51 by a detent 66. The block 65 is attached to and detached from the bobbin 51 by an actuator (not shown).

FIG. 18 shows a winding manufacturing apparatus provided with the winding frame 51 of FIG. The first main shaft 67 on the left and the second main shaft 69 on the right rotate synchronously on the same axis. As shown, when the coil wire is wound from left to right, the first spindle 67
Grips the chuck portion 55 of the reel 51, while the second spindle 69 grips the forming and aligning cup 71. The molding alignment cup 71 has a rectangular cup shape and has a function of aligning coil wires without gaps.

Different sizes of molded alignment cups are prepared for use in winding each layer. Each cup has a shape that fits with almost no gap with the already wound lower coil layer. That is, the cup used for winding the n-th layer has a size that fits the outer circumference of the (n-1) -th layer.
In the example of FIG. 18, the outer peripheral surface of the second layer is fitted in the third layer cup. The cup for the first layer is directly fitted with the former 53.

In FIG. 18, the second main shaft 69 presses the formed alignment cup 71 against the coil wires sequentially wound. Each time the second spindle 69 makes one rotation, the molding alignment cup 71 is moved backward by one pitch. And cup 71
By this, the shape of the coil wire is adjusted.

As described above, the coil wire of the layer being wound is restrained by the molding alignment cup 71, but the lower layer coil portion that has already been wound (the first and second coil portions in FIG. 18).
Layer) is not bound by the cup.

However, the end face collapse prevention block 65 is in contact with the end face of the lower coil portion. Block 65
Since the movement of the lower coil portion in the direction of the winding axis is restricted, it is possible to reliably prevent the coil end face from collapsing.

The molding alignment cup 71 has an escape groove 71a for avoiding interference with the end face collapse prevention block 65 as shown.

When the winding of the winding layer shown in FIG. 18 is completed,
The transition to the next layer winding step is performed in the following procedure. The second spindle 69 is retracted, and the molding alignment cup 71 is removed from the second spindle 69. The second spindle 69 moves forward and the reel 51
Is gripped. Next, the first main shaft 67 separates the winding frame 51 and retreats. Then, the first main shaft 67 grips a forming and aligning cup used for winding the next layer. The upcoming cup has the same configuration as that shown in FIG. 18, but has a shape spread outward by one coil wire. Further, the cup has an escape groove for preventing the lead holder 61 and the end face collapse prevention block 63.

The winding of a new layer is performed in the same manner as described above. When the first spindle 67 moves forward, the coil layer wound up last time fits into the molded alignment cup. Then, the cup is pressed against the coil wire of this winding layer. Next time,
Lead holder 61 and first end face collapse prevention block 6
3 functions to prevent the end face from collapsing.

When the winding of all the layers is completed, the first spindle 67
The second spindle 69 is retracted to the retracted position while the reel 51 grips the winding frame 51. The end face collapse prevention block 65 is removed from the winding frame 51 by an actuator (not shown). The completed coil is removed from the bobbin 51, and the end face collapse prevention block 65 is mounted on the bobbin 51 again. Then, the coil wire is hooked on the lead holder 61 again, and the winding of the next coil is started.

As described above, in this embodiment, by providing the end-face collapse prevention block, the wound coil portion can be effectively prevented from collapsing from the end face. The productivity and reliability of the device can be improved.

Next, FIG. 19 shows a second example of a winding manufacturing apparatus provided with an end face collapse prevention block. Reel 80
Is basically the same as that of FIG.
Is provided with a first end face collapse prevention block 63. However, unlike FIG. 17, the winding form 81 of the winding frame 80 is not provided with a through hole for attaching and detaching the end face collapse prevention block.

In the configuration shown in FIG. 19, the second end face prevention block 82 is provided in the molding alignment cup 84. The end face collapse prevention block 82 has a block support frame 86 that is fitted into the outer periphery of the alignment cup 84 without any gap.
From the end of the block support frame 86, a collapse prevention wall 88 projects so as to be bent inward. The collapsing prevention wall 88 passes through an opening provided in the forming cup 84, and the tip of the collapsing prevention wall 88 reaches a position overlapping with the end surface 81 a of the former 81.

The support portion 86 of the end face collapse prevention block 82 is urged in the winding axis X direction by a spring 90, and the collapse prevention wall 88 is in contact with the end face 81 a of the former 81. The collapse prevention wall 88 supports the end surface of the wound lower layer coil portion, similarly to the device of FIG. 18, thereby preventing the end surface collapse.

In the winding step, the spindle main shaft retreats the alignment cup 84 little by little as described above. But,
The end face prevention block 82 is pressed by the spring 90 and is continuously pressed against the winding end face 81a, so that the collapse prevention function is maintained.

FIG. 19 shows one cup. However, actually, as described above, a plurality of cups having different sizes are prepared for each layer, and are used depending on the layer to be wound.

In FIG. 19, the left spindle holds the reel 80, and the right spindle holds the forming and aligning cup 84. However, of course, the opposite direction is reversed, with the right spindle gripping the bobbin and the left spindle gripping the cup. The former corresponds to the winding of the odd-numbered layers, and the latter corresponds to the winding of the even-numbered layers.

According to the configuration of FIG. 19 described above,
It is possible to effectively prevent the coil portion that is not restrained by the molded alignment cup, that is, the lower layer portion that has been wound, from collapsing from the end face. Further, the configuration shown in FIG. 19 has an advantage that the end face collapse prevention block does not have to be removed from the winding frame when the completed coil is removed from the winding frame.

[0096]

As described above, according to the present invention, it is possible to prevent the occurrence of a curl, which is a cause of the disorder of the alignment of the coil wires in the manufacturing process, and thereby to improve the productivity of the coil. Improvement can be achieved.

According to the present invention, since the coil can be made compact, the size of the motor can be reduced, the output per motor size can be increased, and the motor performance can be improved.

[Brief description of the drawings]

FIG. 1 is a diagram showing an aligned type concentrated winding coil together with a bobbin for manufacturing a coil.

FIG. 2 is a diagram showing a winding start state of a second layer of the coil of FIG. 1;

FIG. 3 is a diagram showing a state where a second layer of the coil shown in FIG. 1 has been wound;

4 is a diagram showing a cross section of each part of the coil in the course of manufacture in FIG. 2;

5 is a diagram showing a cross section of each part of the coil in the course of manufacture in FIG. 3;

FIG. 6 is a diagram showing a state in which an arrangement disorder occurs due to a twist of a coil wire.

FIG. 7 is a diagram showing the cause of the occurrence of a bump in the coil wire.

FIG. 8 is a diagram illustrating an overall configuration of a winding manufacturing apparatus according to an embodiment of the present invention.

FIG. 9 is a diagram showing an example of a coil made by the device of FIG.

FIG. 10 is a diagram showing functions of a row change forming apparatus included in FIG. 8;

FIG. 11 is a diagram showing functions of a layer change inclination preventing device included in the device of FIG. 8;

FIG. 12 is a diagram showing a device for preventing floating of a layer change part included in FIG. 8;

13 is a diagram showing the operation of the floating prevention device of FIG.

FIG. 14 is a diagram illustrating a concentrated winding coil according to a second embodiment.

FIG. 15 is a diagram for comparison and reference to show the effect of the second embodiment.

FIG. 16 is a diagram illustrating a concentrated winding coil according to a third embodiment.

FIG. 17 is a diagram showing a winding frame of a winding manufacturing apparatus provided with a coil end surface collapse prevention block.

FIG. 18 is a view showing a winding manufacturing apparatus provided with the bobbin of FIG. 17;

FIG. 19 is a view showing another embodiment of a winding manufacturing apparatus including an end face collapse prevention block.

[Explanation of symbols]

1 wire bobbin, 3 coil wire, 5 guide roller,
7 reel, 9 flange, 11 column forming device, 13,
15 S-shaped forming claw, 17 layer change prevention device, 19
Inclination prevention plate, 21 Floating prevention device, 23 Floating prevention plate, 31 Floating holding protrusion.

Claims (6)

[Claims] 1. A concentrated winding coil in which coil wires are wound so as to form a plurality of layers, and the coil wires are wound so as to form a row in each layer, wherein the coil wire moves from one layer to the next layer. A concentrated winding coil, comprising: a replacement part and a row replacement part in which a coil wire moves to an adjacent row in the next layer at different positions shifted in a coil circumferential direction. 2. A winding manufacturing apparatus for manufacturing a concentrated winding coil in which a coil wire is wound so as to form a plurality of layers, and a coil wire is wound in each layer so as to form a row. The coil wire is moved to the next position in the next layer, so that the line change portion where the coil wire moves to the next row in the next layer is shifted to another position in the coil circumferential direction. And a tilt prevention device for preventing a tilt of the coil wire by supporting a coil wire portion going up to the next layer by the layer changing portion. Characteristic winding equipment. 3. The concentratedly wound coil according to claim 1, wherein the one layer and the next layer have a switching part at a different position. 4. A concentrated winding coil in which coil wires are wound so as to form a plurality of layers, and the coil wires are wound so as to form a row in each layer. A concentrated winding coil having a portion at a different position in the coil circumferential direction in each layer. 5. A concentrated winding coil in which coil wires are wound to form a plurality of layers, and the coil wires are wound so as to form a row in each layer, wherein the coil wires move from one layer to the next layer. A concentrated winding coil characterized in that a replacement portion is formed at a coil corner. 6. The concentratedly wound coil according to claim 5, wherein a column switching portion for changing a coil wire from one row to an adjacent row is formed at a corner of the coil.