JP2001231224A - Coil mold for rotary machine and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To assure smooth loading to a core by enhancing manufacturing efficiency. SOLUTION: A conductor wise L wound to a reel 12 is fed and is paid out for a length corresponding to a coil 6 in the rolling process. In this case, the wire L is deformed to a flat shape corresponding to the stages of winding of coil 6. Thereafter, the wire 6 is wound for the predetermined number of stages in the coiling process and thereafter is cut for the constant length to obtain a coil 6. Thereafter, the coil 6 is covered in the predetermined shape with an insulator 10 at the surface through the insertion molding. Coil mold 3 thus obtained can be loaded to teeth 8 of the core 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil formed body mounted in a core of a rotating machine and a method for manufacturing the same.

[0002]

2. Description of the Related Art A rotating machine such as an electric motor or a generator usually includes a stator (stator) and a rotor (rotor).
Further, the stator includes a core and a coil mounted inside the core. Since the performance of such a rotating machine becomes higher as the density (occupancy ratio) of the conductors of the coil becomes higher, how to increase the number of turns is an important issue in designing the rotating machine.

[0003] The following method is known as a method of mounting a coil. That is, the stator is
In a member formed by a cylindrical member called a core back and a teeth member incorporated in the core back and having a plurality of teeth radially outwardly, a plurality of elements each formed into an element. Is wound around each tooth, and these are sequentially connected by adjacent ones. In such a case, the space surrounded by each tooth and the core back is a space (slot) for accommodating adjacent coils.
However, since the spacing between the teeth increases with each slot toward the outer periphery, the coil fitted to the teeth has a larger space in the slot as the outer periphery of the slot increases, The space occupancy of the interior gradually decreases. Therefore, improvement of the space factor cannot be achieved at all.

[0004]

Therefore, it is conceivable to form the conductor by crushing the conductor from the stacking direction (the coil height direction) at the time of winding, instead of using the conductor as a round wire. Specifically, if the crushing rate is increased toward the outer peripheral side of the slot, the width of the conductor increases as the outer peripheral side of the slot is increased, and this also leads to an increase in the number of winding steps at the same time. Therefore, the space factor can be improved.

However, a manufacturing method suitable for manufacturing a coil having such an irregular cross-sectional shape has not been developed yet. For example, JP-A-11-2
There is also known a method in which a wire wound around a bobbin is set in a mold, and the outer periphery and the end surface of the wire are compressed by a mold in this state, as in the case of No. 52842. , After cutting the conductor wound on the bobbin to a predetermined length,
Since each step is intermittent, for example, the mold is mounted on a mold, and the formed coil is removed from the bobbin and attached to the teeth portion, the production cannot be performed efficiently.

Further, the above-described method has a problem that the fitting operation is not always smooth because the coil is directly fitted into the teeth portion, that is, the coil itself lacks form stability. . The present invention has been developed in view of such a conventional problem, and has as its object to provide a method of manufacturing a coil molding for a rotating machine having high manufacturing efficiency. An object of the present invention is to provide a coil molded body that can be smoothly mounted on a coil.

[0007]

According to a first aspect of the present invention, there is provided a tooth which is arranged radially inside a core of a rotating machine to partition the inside of the core into a plurality of slots. And a method for manufacturing a coil molded body part of which is accommodated in each of the slots, wherein a wire drawn out from a material supply section has a predetermined cross section corresponding to a winding step. Rolling step of crushing and shaping into a shape, coiling step of winding the formed conductive wire in a plurality of steps, cutting step of cutting the coiled piece into fixed dimensions, and each wound portion of the cut coil And a forming step of forming into a predetermined shape by inserting. According to a second aspect of the present invention, in the first aspect, the conductive wire has a portion which is crushed in a planar shape in the rolling step, and is wound such that the crushed surfaces are stacked in the coiling step. Before the pressing, the pressing step of pressing down the conducting wire from the crushed surface side to regulate the rise of the conducting wire due to the coiling is performed.
Further, the invention according to claim 3 is the one according to claim 1 or 2, wherein the coiling is performed such that the conductor is wound around a winding shaft in the coiling step. When the coil is wound, the edge located on the inner circumferential side is made thinner. Furthermore, the invention according to claim 4 is arranged radially inside the core of the rotating machine so that each of the teeth is divided into a plurality of slots to fit the inside of the core into a plurality of slots. A coil molded body to be housed, in which a coil formed by winding a conductive wire having the same cross-sectional area along a length direction in a plurality of stages, and an insulation molded into a predetermined shape by inserting the coil inside. And the coil is formed by crushing so that the surface facing the stacking direction of the winding stage forms a plane, and the coil is mounted on the tooth portion in the radial direction of the tooth portion. The height of the conductive wire in the winding stage is set to be lower as going from the near side to the far side. The invention of claim 5 is
The device according to claim 4, wherein an outer surface of the insulating portion includes:
An uneven portion that fits between insulating portions of adjacent coil molded bodies is provided along the mounting direction to the teeth portion.

[0008]

According to the first aspect of the present invention, the conductive wire fed out as a continuous body from the material supply unit is crushed and formed into a predetermined cross-sectional shape according to the winding step in the rolling process. After molding, the conductor is transferred to a coiling step, where it is wound into a plurality of stages, and after completion, is cut to a certain size in a cutting step to form a coil. Thereafter, the coil is insert-molded to obtain a coil molded body that can be fitted to the teeth of the core. As described above, according to the first aspect of the present invention, the steps of forming, coiling, and cutting are continuously performed until the coil is manufactured, so that the coil formed body can be efficiently manufactured. .
According to the second aspect of the present invention, in the rolling step, the conducting wire is crushed so that two opposing surfaces are substantially flat. When winding is performed so that the above-mentioned crushed two surfaces overlap in the coiling step, a force acting to form a tapered surface from the outer peripheral side to the inner peripheral side acts at the time of bending operation, so that the conductive wire warps up Thus, the desired coiling cannot be performed. However, claim 2
According to the invention, since the step of pressing the lead wire is set before the coiling step, such a warping deformation can be avoided beforehand and smooth coiling can be performed. Further, at the time of coiling, the inner peripheral side of the conductor is pressed against the winding shaft.
Along with this, the inner peripheral side of the conductive wire is crushed to increase the thickness. However, as in the invention of claim 3, since the inner peripheral edge portion which is pressed against the winding shaft in the rolling step is previously thinned, a coil having a uniform thickness along the width direction after molding is required. can get. Further, in the coil molded body according to the fourth aspect of the present invention, since the height of the conductive wire in the winding step is reduced toward the outer peripheral side of the slot, the conductive wire is wound without performing such processing. Since the number of winding stages can be increased as compared with the case of the above, the space factor in the slot is increased. In addition, since the outside of the coil is covered with the insulating portion having a predetermined shape by insert molding, the form as the coil molded body is stabilized, so that the fitting operation to the teeth portion can be performed smoothly.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. However, in this embodiment,
An example in which the present invention is applied to an assist motor for assisting steering of an automobile will be described.
However, the present invention can be applied to various motors, and can be applied not only to motors but also to various rotating machines including generators.

The assist motor according to the present embodiment is
It has a stator 1 and a rotor (not shown) incorporated in the center of the stator 1. Stator 1 shown in FIG.
Is composed of a core 2 and a coil molded body 3, and
The core 2 includes a core back 4 and a teeth member. The core back 4 is formed in a substantially cylindrical shape, and a large number of slits 7 are formed on the inner peripheral surface thereof at equal angles and over the entire length. The teeth member 5 is a core back 4
It has an annular shape that can be accommodated concentrically inside, and the same number of teeth 8 protrude radially over its entire length corresponding to the slits 7 on its outer peripheral surface. A narrow positioning portion 8A that fits and fits into each slit 7 is formed on the tip end surface of each tooth 8 so as to protrude over the entire length. When the teeth member 5 is accommodated in the core back 4 in a state where each tooth 8 is fitted into the slit 7, a flat fan shape surrounded by the space between the adjacent teeth 8 and the inner wall surface of the core back 4 is formed. The space to be formed is the slot 9.

The coil molded body 3 is assembled to the tooth member 5 while being fitted to each tooth 8, and the tooth member 5 is assembled into the core back 4 in this state. As a result, half of the coil molded body 3 is housed in each of the slots 9 located on both sides of the tooth 8. Further, in this embodiment, the coil formed body 3 is formed by insulating a coil 6 (see FIG. 10) formed by winding a conductive wire into five steps on both the inner peripheral side and the outer peripheral side into a predetermined shape by insert molding. Embedded in the section 10 (FIG. 1
1). The insulating portion 10 is made of a synthetic resin, and in this embodiment, PPS (polyphenylene sulfide) having excellent fluidity and excellent heat resistance is used. Coil molding 3
Is formed so that a flat cross section expanding to the outer peripheral side corresponding to the space shape of the slot 9 forms a fan shape, and a window hole 11 penetrates from the inner peripheral side surface to the outer peripheral side surface. And can be fitted to the teeth 8. Further, both ends 6a and 6b of the coil 6 are drawn out from the lower surface of the coil molded body 3. When the coil molded body 3 is mounted in the core 2, the ends of the pulled-out ones are sequentially connected to each other by a connection fitting (not shown).

As shown in FIG. 12, the degree of crushing of the coil 6 in the coil molded body 3 is set for each winding step, and the degree of crushing in a plane as the core 2 approaches the outer peripheral side is roughly determined. I'm stronger. In this embodiment, the first stage located on the innermost side is made of the material of the conductive wire L and is not crushed as it is, but the second stage to the fourth stage are gradually reduced in thickness, and conversely, are widened. It is gradually crushed strongly to become. The fourth and fifth stages have the same crush ratio. The conducting wire L is composed of a metal wire such as copper and an insulating coating for insulating the surface of the metal wire.

The coil 6 is specifically formed by processing a conducting wire L having a diameter of 2.2 mΦ. However, the thickness of the first stage of the coil formed body 3 remains 2.2 mm. 6mm,
The third step is 1.4 mm, and the fourth and fifth steps are both 1.3 mm. Of course, the degree of crushing depends on the required performance,
It should be variously changed according to the shape of the slot 9, and the one shown here is only an example.

Next, a procedure for forming the coil 6 will be described. As shown in FIG. 3, the coil 6 is formed by processing a round conductor L as described above. That is, the conducting wire L is wound on the reel 12 and can be fed by a pair of feeding rollers 13 arranged in the middle of the forming line. In the present embodiment, a tension roller 14 for applying a back tension (a pulling force in a direction opposite to the feeding direction) to the conductive wire L is also provided near the reel 12. The reason for this is that the drawn-out conductor L has a curl due to the reel 12 and is corrected to secure the linearity of the conductor L.

The conducting wire L passes through a rolling process between the feeding roller 13 and the tension roller 14. The rolling process is provided with upper and lower dies 15a and 15b which can be opened and closed. Opposite surfaces of both dies 15a and 15b are formed so that a length corresponding to one coil 6 can be formed at a time by closing the dies. Surface. As shown in FIG. 4, a plurality of molding recesses 16 are formed on the molding surface in such a manner as to increase the gap size between the two dies in order from the front side (the right side in the drawing) in the feed direction of the conductive wire L. Is crushed by the above-described thickness dimension. In other words, the region indicated by A in FIG. 4 corresponds to the fourth and fifth stages of the coil 6, the region indicated by B corresponds to the third stage of the coil 6,
Are set as regions for processing the second stage of the coil 6 and regions outside the mold indicated as D are regions for processing the first stage of the coil 6, respectively. FIG. 5 shows the conductor L thus processed.
In the figure, A ′ to D ′ correspond to the portions formed in the respective regions A to D described above. When processing is performed on the conductive wire L, each forming recess 16 is formed so that an edge portion on the inner peripheral side when wound in a coiling step described later is slightly crushed along the length direction. The shape is set. This will be described again in the description of the coiling step.

The conductive wire L thus formed undergoes a coiling step. In this embodiment, a pressing step is set before the coiling step. That is, in the rolling process, the upper and lower surfaces of the conductive wire L include portions that are crushed so as to form a plane, but when this is wound in the coiling process, an attempt is made to wind in a plane including the flat surface of the conductive wire L. Therefore, the conducting wire L
Tends to deform so as to form a tapered surface from the inner peripheral side to the outer peripheral side during winding. Therefore, it becomes impossible to pile up and wind the sheet as it is. The pressing step is for regulating the deformation of the conductive wire L for forming such a tapered surface prior to the coiling step.

More specifically, as shown in FIG.
A regulating device composed of the holder 7 and the holder 18 is provided. On the upper surface of the cradle 17, a groove 1 through which the conducting wire L passes is provided.
7A is engraved along the feeding direction of the conductor L. On the other hand, the holder portion 18 is arranged in a direction crossing the groove portion 17A, and one end portion thereof can be tilted with respect to the cradle 17.
Attached by hinges. A pressing means such as a drive cylinder 19 is connected to the other end of the holder 18 so as to apply a force in the pressing direction to such an extent that the feeding to the conductor L is not hindered. Accordingly, the pressing can be continuously performed during the passage of the conductive wire L formed with a plurality of thickness dimensions, and the warpage of the conductive wire L can be reliably restricted.

In the coiling step, the formed conductive wire L is wound in a plurality of steps (five steps). In the coiling step, the winding shaft 20 is arranged in close contact with the side of the feed line L on the feed line. A movable roller 21 is disposed outside the winding shaft 20 with the conducting wire L interposed therebetween. As shown in FIG. 7, the movable roller 21 is configured to rotate around the winding shaft 20 at every predetermined pitch with respect to the conductive wire L. L is sequentially wound around the winding shaft 20. In this case, although not shown in detail, guide means having a slope for guiding upward is appropriately arranged so that the wound conductive wire L does not interfere with a portion to be wound next time.

In the coiling step, the movable rollers 21 are wound in such a manner that the conductors L having different widths are wound in a plurality of stages.
As shown in FIG. 9, the roller portions 21a to 21a having different outer diameters are provided.
The movable roller 21 is movable in the axial direction at predetermined timings corresponding to the width of the conductive wire L in the winding stage, while a plurality of 21d are stacked in the height direction (four stages). It has become. A guide groove 22 is formed in each roller to guide the feeding and winding operation of the conductor L by fitting the edge of the conductor L (also provided on the peripheral surface of the winding shaft 20 as necessary). . And the winding shaft 20 with each roller
The spacing between the guide grooves 22 is a dimension corresponding to the width dimension of the plurality of steps set for the conductive wire L described above.

In the rolling step, the edge of the rolled wire L located on the inner peripheral side of the coil 6 is slightly thinned (T1> T in FIG. 8A).
2). This means that when coiling is performed, the conductor L
The outer peripheral surface of the winding shaft 20 is strongly compressed by the movable roller 21, and in this case, the inner peripheral edge portion L1 is crushed. In this state, the thickness of the conductive wire L becomes uneven in the width direction. In this way, the inner peripheral side edge portion is thinned in advance. By doing so, in the process in which the conductive wire L is pressed against the winding shaft 20 and passes through, the inner peripheral edge of the conductive wire L is crushed, and after the coiling, the thickness of the entire width is made uniform.

After the conductor L has been wound a predetermined number of times as described above, the conductor L is cut by a pair of cutters 23 disposed in front of the winding shaft 20 (cutting step). Thereby, the conductor L is taken out as the coil 6. The coil 6 is subsequently mounted on an insert molding die (not shown), and molten resin (PPS resin) is injected into the cavity in a state where the die is closed.
After the mold is opened, the above-described coil molded body 3 having the predetermined shape is obtained.

As described above, in the present embodiment, the conductor L can be processed as a continuous body up to the coil 6 through the steps of rolling, coiling, and cutting. Therefore, the coil 6 and the coil molded body 3 can be efficiently manufactured without the trouble of transferring between steps. Further, since the coil 6 is formed into a segmented molded body, the coil 6 is mounted more smoothly than the case where the coil 6 is mounted on the tooth 8 alone, and the coil 6 is not damaged. Further, by using such a molded body, heat dissipation is also excellent.

FIG. 13 shows another embodiment of the coil molding 3. Coil molded body 3 in this embodiment
On the outer surface of the insulating portion 10 and the inner surface of the window hole 11, a plurality of uneven portions 24a, b, 27a, b are formed along the width direction, that is, along the direction of fitting to the teeth 8. Uneven portions 24a provided on the outer surface of the insulating portion 10;
In FIG. 14B, as shown in FIG. 14, the phases of the arrangement are shifted on the left and right side surfaces, so that when the coil molded bodies 3 are mounted on the teeth 8, the adjacent coil molded bodies 3 mesh with each other. . By doing so, the mounting of the coil molded body 3 is guided, and the displacement of the coil molded body 3 can be restricted by mutual engagement. In addition, the concave and convex portions 24a and 24b provided in the window hole 11 reduce the contact area with the teeth 8, thereby reducing the fitting resistance and ensuring the smoothness of mounting.

FIG. 15 shows another embodiment of the rolling process. In the above-described embodiment, the rolling of the conductive wire L is performed by a press die, but it is also possible to perform the rolling by a pair of rolling rollers 25 as illustrated. In this case, forming grooves 26 having different widths and depths corresponding to the winding steps of the coil 6 are continuously formed on the peripheral surface of the rolling roller 25. In some cases, a plurality of pairs of the rolling rollers 25 are provided so that the rolling process is performed in multiple stages.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a stator.

FIG. 2 is a plan sectional view of a core.

FIG. 3 is an explanatory view showing a manufacturing process of the coil.

FIG. 4 is a front sectional view showing a rolling process.

FIG. 5 is a plan view showing a conductor after being rolled;

FIG. 6 is a sectional view showing a holding jig.

FIG. 7 is a plan sectional view showing an outline of a coiling step.

8A is a cross-sectional view showing a state before the coil is pressed against the winding shaft, and FIG. 8B is a cross-sectional view showing a state after the pressure contact.

FIG. 9 is a perspective view showing a movable roller.

FIG. 10 is a perspective view showing a coil.

FIG. 11 is a perspective view showing a coil formed body.

FIG. 12 is a cross-sectional plan view of a coil molded body.

FIG. 13 is a perspective view showing a coil molded body according to another embodiment.

FIG. 14 is a front sectional view showing a state of being attached to the teeth member.

FIG. 15 is a perspective view showing another embodiment of the rolling process.

[Description of Signs] 1 ... Stator 2 ... Core 3 ... Coil molded body 5 ... Teeth member 6 ... Coil 8 ... Teeth 15a, b ... Type L ... Lead wire

 ──────────────────────────────────────────────────の Continued on the front page (72) Norihiro Ikeda, Inventor Norihiro, Aichi-gun, Aichi-gun, Togo-cho, Haruki, 1-floor pond, Togo Mfg. Co., Ltd. Inside Togo Mfg. Co., Ltd. (72) Inventor Hidetaka Oshima 1 Hirike, Haruki, Ogo-cho, Aichi-gun, Aichi Prefecture Inside Togo Mfg. Co., Ltd. (72) Inventor Toshihiro Okazaki 1 Toyota-cho, Toyota City, Aichi Prefecture Inside Toyota Motor Corporation F term (reference) 5H603 AA09 BB01 BB02 BB12 CA01 CB02 CB22 CC03 CD21 CD33 CE01 5H615 AA01 BB01 BB02 BB14 PP01 PP07 PP10 PP13 PP17 QQ02 QQ19 QQ27 SS02 SS03 SS19

Claims (5)

[Claims] 1. A radially arranged inside of a core of a rotating machine, which is fitted into a tooth portion that partitions the inside of the core into a plurality of slots, and a part of the teeth is accommodated in each of the slots. A method for manufacturing a coil formed body, comprising: a rolling step of crushing and forming a conductive wire fed from a material supply unit into a predetermined cross-sectional shape according to a winding stage; and winding the formed conductive wire into a plurality of stages. A rotating step, comprising: a coiling step of turning, a cutting step of cutting the completed coil at a predetermined size, and a forming step of inserting each wound portion of the cut coil into a predetermined shape. Of manufacturing a coil molding for a machine. 2. The conducting wire has a portion which is crushed in a plane in the rolling step, and the conducting wire is crushed before being wound so that the crushed surfaces are stacked in the coiling step. The method for manufacturing a coil-formed body for a rotating machine according to claim 1, wherein a pressing step of pressing down from the side of the bent surface to restrict the warpage of the conductive wire accompanying the coiling is performed. 3. In the coiling step, coiling is performed such that the conductor is wound around a winding axis. In the rolling step, when the conductor is crushed, an inner circumference is wound when a coil is wound. The method according to claim 1 or 2, wherein the edge located on the side is made thin. 4. A coil arranged radially inside a core of a rotating machine so as to be fitted into a tooth portion that partitions the inside of the core into a plurality of slots, and a part of the coil is accommodated in the slot. A molded body, comprising a coil formed by winding conductive wires having the same cross-sectional area along the length direction in a plurality of stages, and an insulating portion molded into a predetermined shape by inserting the coil inside. In addition, the coil is formed by crushing so that a surface facing the stacking direction of the winding stage forms a plane, and the coil is closer to a radial direction center side of the teeth portion when mounted on the teeth portion. A coil molded body characterized in that a farther part includes a conductor having a lower height in a winding step. 5. An outer surface of the insulating portion is provided with an uneven portion which is fitted between insulating portions of adjacent coil moldings along a mounting direction to the teeth portion. Item 5. A coil molded product according to item 4.