JP2000245120A - Coil assembly for rotating electric machine and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To shorten the length of the coil end portions of the stator coils, etc., of a motor. SOLUTION: For forming the coil assembly for a rotating electric machine, leads 16 wound and formed into the shape of a squirrel cage beforehand are inserted into the slots of a first core 10 by an inserter 18. Core segments 20 are inserted into positions adjoining in the axial direction of the cylinder of the first core 10 from the radial outside of the cylinder. If these core segments 20 are arranged in a circular form, they constituted a second core 24 having cross section shape orthogonal to the shaft the same as the first core 10. The length of the coil end portions of the leads 16 in a squirrel cage shape, necessary for using an inserter 18 is shortened by forming the second core 24 after insertion. Consequently, it becomes possible to shorten the length of the coil end portions relatively.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil assembly in which a conductor is wound around a core of a motor or a generator to form a coil, and a method of manufacturing the coil assembly.

[0002]

2. Description of the Related Art A rotating electric machine such as a motor or a generator has a coil, and the coil is formed by winding a conductive wire around a core having high magnetic permeability. The state where the conductor is wound around the core to form a coil is hereinafter referred to as a coil assembly. In the case of a motor, this coil assembly creates a rotating magnetic field and is usually a stationary stator. Also, in a generator, a rotating stator generates a current in the coils of the coil assembly by a rotating magnetic field, and is also usually a fixed stator.

The core of the coil assembly has a shape in which protrusions extending in the axial direction of the cylinder are arranged in the circumferential direction on the inner surface of the cylinder, and the protrusions serve as magnetic poles. The conductive wire is accommodated in a concave portion of the gap between the convex portions, a so-called slot, and is wound around one or a plurality of magnetic poles. A method of intensively winding a conductive wire for each magnetic pole is a so-called concentrated winding. A method of winding and winding a conductive wire between a certain slot and a slot having a gap therebetween is a so-called distributed winding. Regardless of the winding method, the so-called coil end portion, which is a portion wound from one slot to another slot, is preferably short. If this portion is long, the copper loss increases accordingly, and the efficiency of the rotating electrical machine deteriorates. Also,
The external shape of the rotating electric machine becomes larger.

One of the methods for manufacturing a coil assembly is to use a device called an inserter. This means that a wire that has been pre-wound into a loop is passed from one end of the core
This is a method in which a coil is formed while being inserted into a slot to be inserted, pulled in the axial direction, mounted on a core, and formed into a coil. According to this method, when the wound conductor is pulled in the axial direction, the coil end portion tends to be longer in order to hold the conductor.

[0005]

As described above, the method using the inserter has a problem that the length of the conductor at the coil end tends to be long, and the efficiency and the size of the rotating electric machine are deteriorated.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and a method of manufacturing a coil assembly capable of shortening a conductor wire of a coil end using an inserter, and a structure suitable for the manufacturing method. It is an object to provide a coil assembly having the following.

[0007]

In order to solve the above-mentioned problems, a method of manufacturing a coil assembly according to the present invention has a cylindrical shape, and comb-shaped irregularities are formed on the inner surface of the cylinder along the circumferential direction. A step of forming a first core having: a step of winding a conductor into a cage shape in accordance with the shape of the core of the rotating electrical machine to be manufactured; and forming the cage in the recess of the first core. Inserting a plurality of core segments into the gap between the cage-shaped conductors at positions adjacent to the first core in a cylindrical axial direction from a radially outer side, and inserting the first core into the cage. Forming a second core having the same cross-sectional shape orthogonal to the axis.

[0008] The second core may be formed at one end of the first core in a cylindrical axial direction.

The first core is divided in a cylindrical axis direction, and the second core is formed by inserting a core segment between the divided first cores. Can be. In this case, in the step of inserting a conductor into the recess of the first core, a spacer is inserted between the divided first cores, and after the conductor is inserted, the spacer is removed, and Widen the gap between the cores,
The core segment can be inserted between the first cores. At this time, the length of the core segment in the cylindrical axis direction can be longer than the length of the spacer.

Further, according to another aspect of the present invention, there is provided a coil assembly for a rotating electric machine having the following structure.

That is, the core comprises a first core having a cylindrical shape, and having the above-mentioned comb-shaped irregularities along the circumferential direction on the inner surface of the cylinder, and a plurality of core segments, and the core segments are joined together. Sometimes, the second core has the same cross-sectional shape as the first core orthogonal to the cylindrical axis, and is disposed adjacent to the first core in the cylindrical axis direction.

Further, the second core may be arranged at one end of the first core in the cylindrical axis direction.

Further, the first core may be divided in a cylindrical axis direction, and the second core may be disposed between the divided first cores.

[0014]

Embodiments of the present invention (hereinafter referred to as embodiments) will be described below with reference to the drawings. FIG. 1 is a process diagram illustrating a method for manufacturing a coil assembly according to the present embodiment. In FIG. 1, the first core 10 is shown in a cross-sectional view including a cylindrical shaft. First core 10
Is formed by laminating electromagnetic steel sheets having a cross section orthogonal to the cylindrical axis. The axis orthogonal cross section of the first core 10 is:
It has an annular portion 12 and a plurality of convex portions 14 provided radially inward on the inner side of the ring and arranged in a comb shape in the circumferential direction. This projection 14 will later become a magnetic pole.

On the other hand, separately from the first core 10, a coil conductor 16 is wound a predetermined number of times to form a cage. One end of the cage coil wire 16 is held by an inserter 18. The inserter 18 has a shape suitable for guiding the cage-shaped coil conductor 16 into the gap between the projections of the first core 10, that is, into the slot.

As shown in FIG. 1A, while the cage-shaped coil conductor 16 is held, the coil conductor 16 is inserted into the slot while the inserter 18 is passed through the inside of the cylinder of the first core 10 in the axial direction. Put in. FIG. 1B shows a state in which the cage-shaped coil conductor 16 is placed in the slot by the inserter 18. Further, in FIG. 1, the coil conductor 16 is moved to the upper side of the first
The upper portion of the core 10 is shaped to lie on the extension of the conductor in the slot. Thereafter, as shown in FIG. 1 (c), a core segment 20 is inserted into the position above and adjacent to the first core 10 from the outside of the first core 10 in the cylindrical radial direction. The core segment 20
Each is substantially T-shaped, and is formed by laminating electromagnetic steel sheets. As shown in FIG. 2, when a predetermined number of the core segments 20 are arranged in a ring shape, the core segments 20 have the same cross-sectional shape orthogonal to the axis as the first core 10. . The magnetic pole 22 is connected to the cage-shaped conductor 16.
1D, the second core 24 is formed at a position where the first core 10 extends upward in the figure as shown in FIG. 1D.

The first core 10 and the second core 24 integrally function as a core of the coil assembly. Then, after the insertion of the cage-shaped conductor 16 by the inserter 18,
Since the second core 24 is formed so as to extend the first core 10, the conductor at the coil end portion is shortened. Until now, the coil end portion, which has not contributed to the generation of magnetic flux, can be effectively functioned by the extension of the core by the second core 24, and the efficiency of the motor is improved. In other words, if the output is the same, the copper loss and the weight can be reduced. Conversely, if the motors have the same external dimensions, the reduction in the copper loss and the increase in the output can be achieved. Furthermore, conventionally, the long coil end was crushed by press molding to reduce the outer shape of the product.
This need not be done or the amount of deformation can be reduced. Thereby, dielectric breakdown due to deformation can be prevented.

FIG. 3 shows another embodiment according to the present invention. In the present embodiment, as shown in FIG. 3A, the first cores 50a and 50b divided into two are provided.
The cage-shaped conducting wire 56 is inserted by the inserter while the spacer 52 is held therebetween. First core 50
As in the embodiment shown in FIG. 1, a and 50b are formed by laminating electromagnetic steel sheets having comb-like irregularities on the inner peripheral side. The spacer 52 is divided in the circumferential direction similarly to the core segment 20 shown in FIG. 2, and has the same cross-sectional shape orthogonal to the axis as the first cores 50a and 50b by being arranged in an annular shape. The shape of the spacer is not limited to the T-shape as shown in FIG. 2, and may be any shape as long as the two first cores 50 a and 50 b have a predetermined axial interval. Good. For example, each ring may be formed by dividing the ring into several parts, and these may be arranged in a ring shape without gaps and with gaps.

The spacer 52 is pulled out radially outward of the cylindrical axis of the core, and at least one of the first cores 50a and 50b is moved to widen the gap as shown in FIG. 3 (b). The core segment 58 is inserted into the widened gap so as to be adjacent to the first cores 50a and 50b. Each of the core segments 58 has a substantially T-shape, similarly to the core segment 20 shown in FIG. Shape. This core segment 58 is
It is inserted from the outside in the radial direction of the cage-shaped conducting wire 54 and is arranged in a ring shape. Thus, the second core 60 is formed.

According to the present embodiment, similarly to the embodiment shown in FIG. 1, the length of the coil end can be reduced, and the efficiency of the motor is improved. Also, as with the embodiment shown in FIG. 1, it is possible to prevent dielectric breakdown due to deformation of the coil end portion. In the present embodiment, particularly, when inserting the core segment 58,
By arranging the conductor between the two first cores 50a and 50b, the conductor can be aligned,
Insertion of the core segment 58 can be facilitated.

[Brief description of the drawings]

FIG. 1 is a process chart showing a method of manufacturing a coil assembly according to an embodiment.

FIG. 2 is a diagram showing a shape of a cross section orthogonal to an axis of a second core 24;

FIG. 3 is a process chart showing a method of manufacturing a coil assembly according to another embodiment.

[Explanation of symbols]

10, 50a, 50b first core, 16 coil conductors, 18 inserters, 20, 58 core segments,
24,60 Second core.

Claims (7)

[Claims] 1. A method for manufacturing a coil assembly of a rotating electric machine in which a conductor is mounted on a core having comb-shaped irregularities and a coil is formed, the method comprising: Forming a first core having a comb-like irregularity along the line; winding a conductive wire into a shape corresponding to the shape of the core of the rotating electrical machine to be manufactured to form a cage; A step of inserting the cage-shaped conductor into the recess of the core; and, at a position adjacent to the first core in the cylindrical axial direction, a gap between the cage-shaped conductor having a plurality of core segments from the outside in the radial direction. And forming a second core having the same cross-sectional shape orthogonal to the axis as the first core. 2. The method of manufacturing a coil assembly for a rotating electric machine according to claim 1, wherein the second core is formed at one end of the first core in a cylindrical axis direction. A method for manufacturing a coil assembly of an electric machine. 3. The method of manufacturing a coil assembly for a rotating electric machine according to claim 1, wherein the first core is divided in a cylindrical axis direction, and the second core is divided into A method for manufacturing a coil assembly for a rotating electric machine, wherein the coil segment is formed by inserting a core segment between cores. 4. The method for manufacturing a coil assembly for a rotating electric machine according to claim 3, wherein, in the step of inserting a conductive wire into the concave portion of the first core, a space between the divided first cores is provided. And a step of extracting the spacer after inserting the conductive wire, and a step of widening a gap between the first cores. The core of the second core formed between the first cores The length in the cylindrical axis direction is longer than the length of the spacer,
A method for manufacturing a coil assembly of a rotating electric machine. 5. A coil assembly for a rotating electrical machine, wherein a coil is formed by attaching a conductive wire wound in a shape corresponding to the shape of the core to a core having comb-shaped irregularities, wherein the core is Is composed of a first core having a cylindrical shape and having the comb-like irregularities along the circumferential direction on the inner surface of the cylinder, and a plurality of core segments. And a second core having the same cross-sectional shape orthogonal to the cylindrical axis as that of the first core and being disposed adjacent to the first core in the cylindrical axis direction. 6. The coil assembly for a rotating electric machine according to claim 5, wherein the second core is disposed at one end of the first core in a cylindrical axis direction. Three-dimensional. 7. The coil assembly for a rotating electric machine according to claim 5, wherein the first core is divided in a cylindrical axis direction, and the second core is a divided first core. A coil assembly for a rotating electric machine, arranged between the coils.