JP2002223549A - Wiring device and coreless motor therewith - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coreless motor which uses a divided mandrel for wiring and a flat press-forming coil produced with a press. SOLUTION: This winding device, which produces a winding for the coreless motor, is structured so as to include the means: (1) a mandrel capable of being divided, (2) a mandrel with opening angle of 120 degrees or larger, and (3) a guide capable of regulating elongation in the crosswise direction during flat forming.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a winding device and a winding method for a coreless motor, a coreless motor manufactured by using the winding device and the winding method, and OA equipment and medical equipment using the coreless motor. It relates to devices and communication terminals.

[0002]

2. Description of the Related Art Conventionally, coreless motors used in OA equipment, medical equipment, communication terminals, and the like are required to be small and light, as represented by vibration pegers, and small motors have been developed and sold by various companies. In recent years, efficient motors have been required in recent years to increase the call waiting time of mobile terminal devices, and the development of motors with excellent motor efficiency as part of energy saving such as OA devices. The development of low-vibration motors is also being studied by various companies because the level of motor vibration in medical equipment is high enough to be felt when the motor vibration is large.

[0003] In such a coreless motor, the applied voltage is low, and there are many Δ-connections as a winding system. The Y connection is almost a Δ connection only for a large motor used for a special motor. This is also because the winding method is suitable for Δ connection.

The winding method of the coreless motor is roughly classified into the following three methods.

(1) Hex winding (2) Diamond winding (3) Honeycomb winding First, hexa winding is also called hexagon winding or Kodak winding. The winding is formed from a self-fusion wire, and the coatings of the winding are fused and fixed by heating or the like, and are formed. In the hexa winding of a hollow cylinder, a part of the winding is aligned in the cylinder axis direction, so a linear conductor in the cylinder axis direction contributing to torque generation exists at the center of the cylinder winding, and the force received by the magnetic pole is effectively Hex winding is the most efficient in three winding systems because it works on the rotating torque. Since a battery-driven motor needs to adopt a method with high motor efficiency and reduce current consumption, most of the coreless motors of portable terminal devices are hexa-turn.

The disadvantage of hexa-winding is that much work is required for processing, and workability is poor.

Next, the rhomboid winding is also called the maxon winding, and is considered to be a subwind of the hexa winding. Since there is no linear conductor in the cylinder axis direction that contributes to the torque, and the conductor is inclined, the utilization efficiency of the winding is worse than that of the hexa-winding. It is no longer the preferred winding method.

[0008] The honeycomb winding is also called a Furl Herba winding. The honeycomb winding does not have a linear conductor in the cylindrical axis direction that contributes to torque similarly to the rhombic winding, and thus has a lower winding utilization efficiency than the hexa winding.

A coreless motor used for a vibration motor of a mobile phone of a recent communication device is a utility model registration 3007.
571, JP-A-7-298590 and JP-A-7-284259, the use of a hexa-winding winding to improve the characteristics and reduce the current consumption, Products that extend battery life and extend talk time and standby time have been released to the world. This prolonged talk time and standby time is also one of the product development concepts.

[0010] However, this hexa winding has many steps in processing, and the workability of processing is not very good. In various respects, efforts have been made to improve work efficiency. In general, most of the emphasis is on the wire processing part. For example, a ring-shaped coil connection part is provided in a commutator riser part as in Japanese Patent No. 2913838 to facilitate connection.

The hexa-winding requires a considerable amount of man-hours, such as a winding operation, a tape temporary fixing operation, a flat pressing operation, a curling operation, and an annealing operation.

There is a need to improve the workability of the winding process while improving the characteristics of the hexa-winding.

[0013]

SUMMARY OF THE INVENTION To solve the problem,
It is necessary to explain the winding work process of the hexa winding of the conventional example in more detail.

The winding operation will be described. In the case of hexa winding, winding is wound around a hexagonal mandrel (also referred to as a bobbin) in an aligned manner.

Next, the tape temporary fixing operation will be described.
While being wrapped around the mandrel, it is temporarily fixed with tape to prevent collapse. In that state, remove it from the hexagonal mandrel. The mandrel is hexagonal and slightly tapered while maintaining a hexagonal cross section. Conventionally used 1/100 to 1/1000
, And could be used without any problem in the case of a winding having a relatively large wire diameter (φ1.0 or more).

Next, the flat work will be described. A pair of hexagonal opposing surfaces of the winding removed from the mandrel are turned in the axial direction of the mandrel to form a flat plate. At this time, a pair of opposing surfaces is determined as a surface on which the tape is affixed, such that the tape is affixed thereto.

Further, the curling operation will be described. The flat-shaped winding is wound around a curling rod (also called a molded rod or a rod). At that time, a tape is wound around the curled outer periphery. By winding the tape, when it is taken out from the curling rod, the formed outer diameter of the winding after the curling is kept stable and the variation is small. In addition, workability in the annealing process in the next step is improved, and troubles such as disconnection in the work are not generated.

Next, the annealing operation will be described. The winding in the state of the curling molding is heated to strengthen the molding. Since the winding uses a self-fusion wire,
By heating, the windings are fused to each other, so that the windings are not separated. Due to the tape used in the previous process, the tape becomes stronger.

Since the mandrel has a hexagonal real axial cross section, the hexagonal mandrel is tapered in order to extract the winding from the mandrel. Because the hexagon at the beginning of the winding on the mandrel and the hexagon at the end of the winding are different in size due to the taper, the flat forming state of flattening the winding at the beginning of the winding The width at the end of the winding is shorter than the width. Therefore, when curling, the winding start part and the winding end part are overlapped, a discontinuous curled molded body is formed, and the resistance value of the winding differs depending on the location. And the generated torque in each phase varies. As the size of the motor becomes smaller, the generated torque value becomes relatively smaller, and the variation in the torque becomes less favorable for the starting performance and the control performance.

The mandrel has a hexagonal shape and is slightly tapered while maintaining a hexagonal cross section.
Previously used taper had a taper of 1/100 to 1/1000, and could be used without any problem in the case of a winding having a relatively large wire diameter (φ1.0 mm or more). In the case of the above motor, if the winding diameter is less than φ1.0 mm, the winding collapses when the winding is removed from the mandrel. As described above, the variation in the resistance value increases.

For this purpose, the mandrel is made into a split type without a hexagonal cross section of a real shaft, and a mandrel having no taper degree is devised so that the split type can be used, and the mandrel is wound by the winding device. An attempt is made to provide a coreless motor using windings.

[0022]

SUMMARY OF THE INVENTION In order to achieve the above-mentioned object, the present invention incorporates a device into a process of improving characteristics in a winding process.

The motor characteristics can be improved while the size of the motor is determined, as long as the length of the linear conductor in the cylindrical axis direction in the hexa winding can be increased. Since the width of the flat formed flat winding is determined by the motor size, it is necessary to reduce the ratio of the inclined portion to the winding. The efficiency is improved by increasing the opening angle of the mandrel so that the width dimension of the inclined portion becomes shorter.

The conventional mandrel is a regular hexagon, and the opening angle of the mandrel is 120 degrees.

Even with a real-axis mandrel, the opening angle of the mandrel is set to 120 degrees or more in order to lengthen the linear conductor portion in the axial direction.

To increase the length of the straight portion, the width of the inclined portion must be reduced. However, in the process of flat forming, the inclined portion extends and becomes longer than the width of the inclined portion of the mandrel. The length of the axial straight conductor portion is determined in consideration of the extension of the inclined portion.

In the case of a small-sized motor, the extension of the inclined portion has a large effect on the characteristics. Therefore, a relatively long straight conductor can be obtained by restricting the extension and performing flat forming.

To briefly summarize the above, regarding the winding apparatus for manufacturing the winding of the coreless motor, (1) the mandrel is divided. (2) The opening angle of the mandrel is set to 120 degrees or more. However, the opening angle of the mandrel is 170 degrees or less. (3) A guide is provided to control the elongation in the width direction during flat forming.

By incorporating one or more of the items, a new winding can be realized, and a coreless motor using a winding made by this winding device can improve motor characteristics.

[0030]

BEST MODE FOR CARRYING OUT THE INVENTION According to the first aspect of the present invention, a hexagonal winding is wound around a winding mandrel, and the winding is wound around the mandrel. After temporarily attaching tape to the surface and temporarily fixing the same, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed winding is curled to form a cylindrically shaped armature. The winding angle of the winding mandrel for manufacturing the armature is 121.
It is a winding device of a mandrel that is not less than 170 degrees and not more than 170 degrees, and the length of the straight conductor part in the cylindrical axis direction in the hexa winding can be lengthened while the specification of the winding is determined, and the winding of the inclined part It has the effect that the length ratio occupied by the part can be reduced.

According to a second aspect of the present invention, a hexagonal winding is wound around a winding mandrel, and a tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. A coreless motor using an armature that has been temporarily fixed, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed flat pressing forming coil is curled and cylindrically formed. In the above, using a mandrel having an opening angle of the winding mandrel for manufacturing the armature of 121 degrees or more and 170 degrees or less, the opening angle of the inclined portion of the flat press forming coil at the time of flat pressing is 121 degrees or more. This is a coreless motor using an armature characterized by having an angle of 170 degrees or less, and the length of the linear conductor in the cylinder axis direction in hexa-winding with the winding specifications determined It can be long, in order to be able to reduce the length ratio of the winding portion of the inclined portion has the effect that it is possible to improve the motor characteristics among the size is determined.

According to a third aspect of the present invention, the winding is wound around the winding mandrel in a hexagonal shape, and a tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. After temporarily fixing, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed flat-formed forming coil is curled to produce a cylindrically formed armature. The winding device according to claim 1, wherein a winding mandrel for manufacturing the armature is divided into two, and a gap is provided between the two mandrels. The mandrel spacing can be adjusted by changing the gap of the split type mandrel, and for the split mandrel, the mandrel is adjusted so that the gap is zero, and the winding While maintaining the wound shape, an effect that can be easily withdrawn from the mandrel.

According to a fourth aspect of the present invention, a hexagonal winding is wound around a winding mandrel, and tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. A coreless motor using an armature that has been temporarily fixed, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed flat pressing forming coil is curled and cylindrically formed. The winding mandrel for manufacturing the armature is 2
The coreless motor according to claim 2, wherein a gap is provided between the two mandrels, and a mandrel interval is adjusted by changing a gap between the divided mandrels. In addition to the split mandrel, the mandrel can be easily removed from the mandrel while maintaining the wound shape by aligning the mandrel so that the gap is zero. Since the mandrel is not formed in a tapered shape, there is an effect that a core-rel motor can be formed using a winding having no variation in characteristics.

According to a fifth aspect of the present invention, the winding is wound around the winding mandrel in a hexagonal shape, and tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. After the temporary fixing, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed winding is curled to produce a cylindrically shaped armature in a winding device. The winding mandrel for manufacturing the armature is divided into two, and the mandrel is formed with two inclined surfaces having an angle that determines the opening angle of the winding, and one end of the inclined surface is already formed. 2. The winding device according to claim 1, wherein the mandrel has a parallel portion facing one of the mandrels, and a distance between the parallel portions is set to a length corresponding to an electrical angle of 180 degrees of the armature. The split tie Of Using mandrel, on top that can be easily adjusted mandrel interval, divided mandrel electrical angle mandrel width of the armature 18
A relatively long mandrel width can be ensured because the length is set to be equal to 0 degrees, and the parallel portion can be lengthened because the mandrel opening angle can be increased. Having.

According to a sixth aspect of the present invention, the winding is wound around the winding mandrel in a hexagonal shape, and the tape is stuck on two inner surfaces of the six surfaces in a state where the winding is wound around the mandrel. After being temporarily fixed, the wound winding is pulled out from the mandrel, and the tape is flat-pressed up and down, and the flat-pressed winding is curled, and a coreless motor using a cylindrically formed armature is used. A winding mandrel for manufacturing the armature is divided into two, and the mandrel is formed with two inclined surfaces having an angle that determines an opening angle of the winding, and one end of the inclined surface is the other. A mandrel configured with a parallel portion facing the mandrel of
The coreless motor according to claim 2, wherein a distance between both ends of the inclined surface is defined to be a length corresponding to an electrical angle of 180 degrees of the armature, and by using a split type mandrel, In addition to being able to easily adjust the mandrel interval, the mandrel width of the divided mandrel is defined to be a length corresponding to the electrical angle of 180 degrees of the armature, so that a relatively long mandrel width can be secured. Since the opening angle of the mandrel can be increased, the length of the parallel portion can be increased, and the coreless motor having good motor characteristics can be obtained.

According to a seventh aspect of the present invention, the winding is wound around a winding mandrel in a hexagonal shape, and a tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. After the temporary fixing, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed winding is curled to produce a cylindrically shaped armature in a winding device. In the step of flat pressing, the wound winding is formed by forming and falling, and the winding is regulated so as not to spread in a direction perpendicular to the flat direction on both sides of the winding in parallel with the flattening direction. It is a coreless motor using an armature using the windings, and the length of the linear conductor in the cylindrical axis direction can be lengthened. Can be lowered,
A coreless motor with excellent motor characteristics can be made, and the length of the sloped part can be reduced by regulating press.Therefore, a winding length close to the mandrel distance can be made.
Once the winding length is determined, the mandrel can be designed in a short time.

According to an eighth aspect of the present invention, a hexagonal winding is wound around a winding mandrel, and tape is attached to two facing surfaces of the six surfaces in a state where the winding is wound around the mandrel. After the temporary fixing, the wound winding is extracted from the mandrel, flat-pressed so that the tape is up and down, and the flat-pressed winding is curled to produce a cylindrically shaped armature in a winding device. In the step of flat pressing, the wound winding is formed by forming and falling, and the winding is regulated so as not to spread in a direction perpendicular to the flat direction on both sides of the winding in parallel with the flattening direction. This is a winding device that manufactures an armature using the winding by flat pressing.The length of the linear conductor in the cylindrical axis direction can be increased, and the ratio of the length of the winding portion of the inclined portion Coil with excellent motor characteristics In addition to the restriction press, the extension of the length of the inclined part is reduced by using a press, so that a winding length close to the mandrel distance can be made, and once the winding length is determined, the design of the mandrel can be completed in a short time Has the effect of being able to.

According to a ninth aspect of the present invention, in the flat pressing step, the wound winding is formed by forming and falling, and the winding is wound on both sides of the winding in a direction parallel to the flattening direction. 9. An apparatus for flat pressing with restriction so that it does not spread in a right angle direction, wherein a cut-out portion for escaping the terminal portion is provided in the terminal portion of the winding so that the restriction of the restriction press does not reach. The terminal unit is not press-regulated because the terminal unit is housed in the notch and pressed. Pressing the terminal with no notch in a folded state can easily cause the wire or terminal to break, and may damage the terminal when the pressed terminal is removed after pressing. Has the effect that there is no.

According to a tenth aspect of the present invention, in the flat pressing step, the wound winding is formed by forming and falling down, and the winding is wound on both sides of the winding in a direction parallel to the flattening direction. 8. An apparatus for flat pressing with restriction so as not to spread in a right angle direction, wherein a notch for escaping the terminal part is provided in the terminal part of the winding so that the restriction of the restriction press does not reach. This is a coreless motor using an armature using the above winding, and the terminal portion is not regulated and pressed by storing and pressing the terminal portion in the cut portion.
Pressing in a state where the terminal part that has no cut-out part is folded is likely to cause the wire and the terminal part to break, and also the risk of damaging the terminal part when removing the pressed terminal part after pressing Has the effect that there is no.

According to the eleventh aspect of the present invention, a hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is affixed to two of the six surfaces facing each other. After fixing, the wound winding is pulled out from the mandrel, flat-pressed so that the tape is up and down, and in the coreless motor using an armature cylindrically formed by curling the flat-pressed forming coil that has been flat-pressed. In the step of flat pressing, the wound winding is formed by forming and falling, and the winding is regulated so as not to spread in a direction perpendicular to the flat direction on both sides of the winding in parallel with the flattening direction. Core press using a flat press forming coil and an armature using a flat press forming coil again to form a terminal part of the winding. In addition to being able to press the thickness of the flat press forming coil corresponding to the corner part of the regulated press to a predetermined thickness, the pressing is also performed on the terminal part, so that the predetermined thickness is obtained. This has the effect that a coreless motor having a uniform air gap is possible.

According to the twelfth to fourteenth aspects of the present invention, OA equipment, medical equipment and communication terminals having more excellent characteristics can be obtained by using the coreless motor of the present invention.

[0042]

Embodiments of the present invention will be described below with reference to the drawings.

(Embodiment 1) FIG. 1 is a diagram showing a split type mandrel of a winding device according to an embodiment of the present invention. Figure 1
2A is a front view, FIG. 2B is a top view, and FIG. 1C is a left side view. FIG. 2 is a sectional view of a winding-using portion of the split type mandrel of FIG. FIG. 3 is a sectional explanatory view of the mandrel when two of the split type mandrels shown in FIG. 1 are set in a winding device.

1, 2 and 3, 1 denotes a mandrel, 2 denotes an inclined portion, a denotes an opening angle of the mandrel, b denotes an opening width of the mandrel, c denotes a thickness of the inclined portion of the mandrel, d
Is the parallel part thickness of the mandrel.

The mandrel shown in FIG. 1 has an opening angle a and has an inclined portion defined by the opening width b of the mandrel. Therefore, as shown in FIGS. Is set by the opening angle a of the mandrel and the opening width b of the mandrel.

[0046]

(Equation 1)

The opening width b of the mandrel is a value that can be obtained by design from the specifications of the winding. The design will be described later.

As shown in FIG. 3, two split type mandrels are used.
If the mandrel of the winding is used by using a single mandrel, the image is like a conventional hexagonal real mandrel divided into two mandrels of two divided types and combined into one mandrel for winding. The opening angle of the third mandrel is larger than 120 degrees of the regular hexagon, and the cross section of the two mandrels does not become a real axis state. That is, as shown in FIG. 3, the mandrel is aligned with the gap g. E shown in FIG. 3 indicates a mandrel interval. The mandrel interval e is set to be shorter than the length in the state of flat press forming (or flat press or flat forming). Since this set amount is determined at the time of adjustment of the winding device, it is not easy to adjust the mandrel interval e when the actual shaft state is set. Adjusting the mandrel interval e in adjusting the state of the winding is often performed in the winding setting operation. In the case of the split type mandrel as shown in FIG. 3, the mandrel interval e can be adjusted by changing the gap g. Therefore, the split type mandrel can be easily adjusted. However, in the case of the real shaft type mandrel as in the conventional example, the mandrel interval cannot be adjusted because there is no equivalent to the gap g. This is one of the major features of the split type mandrel.

The winding operation process will be described below. As described in the conventional example, the order of the winding operation, the tape temporary fixing operation, the flat plate pressing operation, the curling operation, and the annealing operation is performed. However, work contents are different in the embodiment.

FIG. 4 is a view for explaining a winding winding step using two split type mandrels.

The winding operation is performed by two divided mandrels 1
The winding is wound in a line from one end of the hexagonal mandrel 1 formed on the mandrel 1 so as to form a terminal portion (or terminal processing portion) of the winding when a predetermined number of turns is reached. The winding is wound again from the winding part. Do the work on the same mandrel until the required number of phases is reached.

This will be described with reference to FIG. 4 which is a three-phase winding. Reference numeral 3 denotes a first phase winding, 4 denotes a second phase winding, 5 denotes a third phase winding, and the first phase winding 3 and the second phase winding 4 are terminals. It is connected via the unit 7. The second-phase winding 4 and the third-phase winding 5 are connected via a terminal 8. The winding process aims at fixing the winding start end 10 of the winding at one place of the mandrel so that the winding does not move due to the tension of the winding during the winding operation. When the fixing process of the winding start end of the winding is completed, firstly, the mandrel is provisionally wound about one round to form the provisionally wound portion 11. Subsequently, the terminal portion 6 is formed at the corner of the opening angle of the mandrel, and the winding of the first phase winding portion 3 is started to be wound around the temporary winding portion 11. When the predetermined number of turns is completed, the terminal portion 7 is formed at the corner on the same side as the opening angle of the mandrel on the terminal portion 6 side, and then the second phase winding portion 4 is connected to the first phase winding portion. The winding is started from the part 3 and wound by a predetermined number of turns. Further, the terminal portion 8 is formed at the corner of the opening angle of the mandrel on the same side as the terminal portions 6 and 7, and the winding of the third phase winding portion 5 is started from the second phase winding portion 4. Then, the terminal part 9 is formed by winding a predetermined number of turns. Furthermore, it is wound about one turn to form a temporary winding portion 13 at the end of winding,
Terminate the end of the winding. The end 12 of the end of the winding is obtained by cutting from the coil bobbin. In this cutting, the cutting position is more stable when the tension is applied to the winding to some extent, so that the finish of the winding can be stably performed after the tape is temporarily fixed.

Next, the tape temporary fixing operation will be described.
FIG. 5 is an explanatory diagram showing a state where the winding is wound around a mandrel and temporarily fixed with tape. While being wound around the mandrel 1, it is temporarily fixed with a tape 14 (also referred to as a temporary fixing tape) to prevent collapse. The position of the tape 14 to be temporarily fixed is determined by the faces forming the opening angle (that is, there are actually two faces forming the opening angle, and since there are two opening angles, four faces out of the six faces of the hexagon). 2) other than 15, 15 and 16
It is. The two surfaces 15 and 16 are configured to face each other, and the surface to which the tape 14 is attached is configured in parallel with the line connecting the corners of the opening angle. Therefore, when flat press forming is performed in the next process, the tape 14 is turned up and down. Flat press forming so as to be positioned, that is, the two surfaces 15 and 16 are vertically overlapped.

The width temporarily fixed with the tape 14 is shown in FIG.
+ 2d. The width g1 of the tape 14 is determined on the basis of g + 2d, but is slightly adjusted in accordance with the finishing condition of the winding in the pressing step of flat press forming in the next step. Tape 1
The width g1 of No. 4 is determined in a range that satisfies the following relationship.

[0055]

(Equation 2)

The relation of g <g1 in the above equation is that, when the tape 14 is attached to the wound winding, the tape 14 is placed on the winding, the tape 14 is pressed from above, and the tape 14 adheres to the winding. The width of the tape 14 is determined so that the tape 14 hangs over the parallel portion of the split mandrel because a solid member needs to be interposed under the winding to be pasted. . The width d of the parallel portion of the mandrel is determined in consideration of the workability of the tape application and the winding process.

In the above equation, (g + 2d) / 2 <g1 <(g + 2
The relation d) is a relational expression that manages the tape width, since if the tape width is small, the windings that are not fixed with the tape 14 and are wound in an aligned manner will be separated in the subsequent work process. If it is disjointed, the thickness of the completed winding locally changes, so that the distance from the magnet changes or, at worst, it comes into contact with the magnet. In practical use, the tape width is set to about 80% of (g + 2d) in the relationship of (Equation 2).

The length f1 of the tape includes the first phase winding part 3, the second phase winding part 4, the third phase winding part 5, the winding start temporary winding part 11, the winding start end 10, and the winding end. Since the temporary winding portion 13 and the winding end 12 are also fixed by the tape 14, the winding length f is longer than the winding length f of the winding. That is, the following relationship is established.

[0059]

(Equation 3)

Next, the winding is extracted from the mandrel 1.
When the mandrels are aligned so that the gap g (FIG. 3) becomes zero for the divided mandrel 1, the winding becomes tape 14
, And can be easily removed from the hexagonal mandrel while maintaining the wound shape. In the case of a real shaft mandrel as in the conventional example, the cross section is slightly tapered while maintaining the hexagonal shape, so that the mandrel can be pulled out for work. Since the mandrel interval e varies depending on the position of the mandrel due to the influence of the taper, a problem easily occurs in that the resistance value between the phases of the winding and the induced voltage between the phases differ. Such a correlation variation can be eliminated by using a split type mandrel. In the case of the split type mandrel, the mandrel interval e is the same at any position of the mandrel. Therefore, there is almost no variation in the resistance value and the induced voltage between the phases unlike the conventional example.

Next, the flat work (or flat press forming work or flat press work) will be described. A pair of hexagonal opposing surfaces of the winding removed from the mandrel are turned in the axial direction of the mandrel to form a flat plate. The opposing surface indicates the surface to which the tape is applied during the temporary fixing operation with the tape. Rather than simply forming on a flat plate as in the conventional example, a plate-shaped winding is formed in two processes, a regulation guide press process and a flat plate press process. The regulated guide press process and the flat plate press process will be described below.

FIGS. 6 and 7 show an example of the regulation guide in the regulation guide pressing step. When a pair of hexagonal opposing surfaces of the winding pulled out from the mandrel is tilted in the mandrel axial direction, the restriction guide regulates the spreading dimension of the winding in the direction perpendicular to the direction in which the opposing surface is tilted. Is a guide. The regulation guide will be described based on the regulation guide 17 shown in FIGS. 6 and 7, reference numeral 18 denotes a pedestal for the regulation guide; 19, a wall guide for the regulation guide;
0 is the wall guide of the other regulating guide, 21 is the punch of the regulating guide, 22 is the convex portion of the punch, and the distance h between the concave portions 23 formed by both wall guides is determined based on the mandrel interval e. The relationship is that the conductor wire diameter dc of the winding (or coil) is 0.05 mm or less, 0.075 mm or less, and 0.
Depending on the case of 1 mm or less and 0.2 mm or less, the following is achieved.

[0063]

(Equation 4)

A hexagonal winding 24 (shown only in FIG. 6) is installed in a concave recess 23 formed by the two wall guides 19 and 20, and the winding is pressed by a convex punch 22. At this time, even if the terminal of the winding is pressed, the wall guide 1
Wall guide 19, so as not to be regulated by 9, 20
A notch 25 that can accommodate a terminal portion is formed on one side of 20. In FIG. 7, the notch 25 is provided on the wall guide 20. In the case of a three-phase winding as shown in FIG.
5 is required at four locations and is an example of a regulation guide for a three-phase winding. Therefore, FIG. 7 also has cutouts represented by reference numerals 25a, 25b, 25c, and 25d. The terminal portion is stored in the cut portion 25 and pressed to prevent the terminal portion from being regulated. Since the terminal part corresponds to the terminal part of the winding phase, it is necessary to connect the terminal part to the outside. Therefore, if the terminal part cannot be connected, the winding will be defective. In a regulated press having no cut-out portion 25, the press is performed in a state in which the terminal portion is folded on the regulated press, and the surrounding lines and the terminal portion are disconnected due to the overlapping of the terminal portions. In addition, there is a risk that the terminal may be damaged when the terminal is removed from the overlapped and pressed part. As a countermeasure, the terminal portion is accommodated in the notch 25 from the restriction portion of the wall guide of the restriction guide 17 so that the terminal portion does not have a problem due to the restriction press.

The width of the cut 25 is designed in consideration of the following.

When the winding is pressed, it is considered that the height of the winding becomes the opening width b of the mandrel if the wire diameter of the winding is ignored, and the height of the winding becomes zero by pressing. Since the terminal portion is located at the center of the winding height, the terminal portion has a height of (b / 2). In order for the winding height to be zero by pressing with the regulation guide, the winding does not simply move up and down to zero, but the winding slides on the press surface and the height Becomes zero. FIG. 8 is a model diagram of a locus of a winding in which the winding height becomes zero in the pressing step. If it demonstrates using FIG. 8, a winding will draw a locus | trajectory which made the distance of a winding height direction a radius, and height will be set to zero. FIG. 8 shows that in the pressing step, the upper winding 26 and the lower winding 27 are positioned with the winding 26a and the winding 2 before being pressed.
7 and is straight with respect to the pressing direction. It is considered that the pressing causes the winding 26 to move from the position of the winding 26a to the position of the winding 26b along an arc locus centered on the position of the winding 27. Then, the terminal portion 28 moves along the locus of a circle having a radius (b / 2). From the position of the terminal portion 28a before pressing, the terminal portion 28b
Move to the position. Therefore, since the terminal portion 28 has moved by (b / 2) in the lateral distance, the width of the cut portion should be (b / 2) so as not to hinder the movement of the terminal portion at the cut portion. Only) is needed. But,
Since the press model is a model in which the winding slides only on one surface, the lateral movement of the terminal is (b / 2).
However, since both surfaces of the winding slide relatively, it can be determined from the model that the moving amount of the terminal portion is (b / 4). Actually, the sliding may not have the same amount of effect on both sides, so the width f2 (shown in FIG. 7) of the cut portion is designed according to the following relationship.

[0067]

(Equation 5)

Next, the flat pressing process will be described. In the description of the process, the pressed planar winding is distinguished as a flat forming coil. The regulated pressing flat forming coil is flat pressed on the upper and lower flat surfaces to form a flat forming coil having a predetermined thickness. One reason for using the conventional flat press is that the press at the corner of the regulated press cannot be pressed to a predetermined thickness due to the influence of the wall guides 19 and 20, so that there is no regulated wall guide 19 or 20. Need to be pressed. Further, as another reason, since the terminal portion is not subjected to the regulation press, the dimension is not restricted by the width f2 of the cutout portion 25 of the relief, and the winding becomes longer than the distance h dimension of the wall guide. In order for the thickness to be such that the press is not applied, it is necessary to press without the wall guide of the regulating press so that the thickness is within the specified range. The flat forming coil part corresponding to the cut part is not regulated by the restriction press, but the restriction is applied to the parts other than the cut part, so that the cut part slightly protrudes from the wall guide distance h due to the effect of the restriction. Dimensions do not have the dimensions of a flat press without any restrictions.

The dimensions of the flat press forming coil at the time of the flat press as in the conventional example and when the regulating press is inserted are as shown in the following table.

[0070]

[Table 1]

The width of the parallel portion in Table 1 corresponds to (g + 2d) of the mandrel in FIG. 3, the width of the inclined portion is related to c of the mandrel, and the width of the inclined portion is valued due to both the inclined portions. Is 2c
Is equivalent to Even though the windings before pressing are the same, the width of the inclined portion differs depending on the presence or absence of the regulating press. Therefore, since the size of the inclined portion changes, the overall width of the winding differs. Since the width of the parallel portion is a value that does not depend on the presence or absence of the regulating press, it is considered that the setting of the mandrel of the winding is directly reflected.

The distance e of the mandrel in Table 1 is 11.
2 is the data when the wall guide distance of the regulating press is set to 11.4. With a flat press alone without a regulated press, pressing a winding with a mandrel distance e,
The entire width of the press of the winding is considerably different from e. The length and diameter are important in the winding dimensions determined in designing the motor winding. The length of the winding in the design corresponds to the entire width of the winding. Therefore, increasing the length of the parallel portion within the entire width of the winding is a means for improving the characteristics of the motor. It is necessary to determine the distance of the mandrel in consideration of the change in the slope width in order to make the winding length specified in the motor design rule. To shorten the distance e of the mandrel is to shorten the straight portion of the winding, and the characteristics are degraded. From the results in (Table 1), in order to make the whole winding width the same as that of the regulation press only with the flat press, it is necessary to subtract a difference of 1.9 mm from the length of the parallel portion from the length of the parallel portion. Adjust the distance e of the mandrel so that the width becomes 2.3 mm. In other words, the length of the parallel part is changed from 2.3 mm to 2.3 mm to avoid the restriction press, so that 45 mm
% Of the parallel portion. It will also be considerably reduced from the motor characteristics.

According to (Table 1), by using the regulated press,
It can be seen that the length of the ramp can be similar to the size of the winding in the mandrel. The restriction press is performed because the difference between the entire width of the restricted press winding and the mandrel distance e can be reduced, so that the linear portion can be lengthened and the characteristics of the motor can be improved.

As described in the above embodiment, by performing the regulating press, the ratio of the linear portion occupying the entire width of the winding can be increased, and the winding of the regulating press is used for the winding of the motor. Thereby, the characteristics of the motor can be improved. Table 2 shows examples of differences in motor torque characteristics depending on the presence or absence of the restriction press.

[0075]

[Table 2]

Two examples in the case of press regulation are “Yes 1”,
An example in which no press is performed is shown in Table 2 with a distinction being made as "Yes 2" and no control press. From (Table 2),
By controlling the press, the motor torque characteristic Kt is about 5 to
It can be seen that it is improved by about 10%.

Next, a curling operation for curling the flat forming coil into a cylindrical shape after the flat pressing step will be described below. A flat-formed coil formed by flat pressing is wound around a curling rod, curled by a roller so as to be in close contact with the curling rod, and then a curling tape (which is distinguished from a temporarily fixed tape as a curling tape) is wound around the outer periphery. By winding this curling tape, when the winding is taken out from the curling rod, the forming outer diameter of the winding after curling is kept stable, and the variation in the cylindrical diameter of the curled cylindrical winding is reduced. Become small.

Next, in the winding in the state of the curling molding, an annealing operation is performed to heat the winding to strengthen the molding. The annealing operation will be described below. Since the windings use self-fusing wires, the windings are fused together by heating. Therefore, the cylindrical curling-formed winding is placed in a cylindrical housing, and placed in an environment of about 130 degrees. Since the self-fused wires cannot be fused together due to the temperature, take out from the housing. After annealing, a cylindrical winding is manufactured. Further, since the curling tape is wound, if the adhesive of the tape is also a thermosetting adhesive, the cylindrical molding becomes stronger. The width g2 of the curling tape has the following relationship similarly to the relational expression of the width of the temporary tape.

[0079]

(Equation 6)

When the curling tape is applied, it is easy to attach the curling tape because of the presence of the curling bar, and it is considered that there is no actual problem with the width smaller than the lower limit. Therefore, a curling tape having the same width as the temporary fixing tape or a width larger than that is used. From (Equation 2) and (Equation 6), the width of the temporary fixing tape or the curling tape to be applied at the time of the hexagonal winding is smaller than the width of the parallel portion when the hexagonal winding is pressed. . Since the thickness of the winding is thin at the parallel portion, even if a tape is applied, the thickness of the winding is hardly affected. A thin tape is used so that the thickness of the winding does not increase. As an example, a substrate having a thickness of 25 μm is used.

FIG. 9 is a sectional view of a coreless motor using the above windings. Since the coreless motor is a vibration motor used for a portable terminal device, a weight is attached to the tip of the shaft 33. In FIG. 9, a concave concave portion 30 is provided on one end surface side of the hollow cylindrical chassis 29, and a sintered metal 31 is press-fitted into the concave portion 30, and a guide pin is provided to prevent deformation of the inner diameter due to press-fitting. Insertion suppresses deformation so that the inner diameter of the sintered metal 31 does not interfere with use. When the guide pins are pulled out, the sintered metal 31 is prevented from protruding abnormally, and the coaxiality between the hollow cylindrical chassis 29 and the inner diameter of the sintered metal 31 is controlled. The hollow cylindrical chassis 29 has a shaft through-hole 32 formed therein. This shaft through hole 3
Reference numeral 2 is formed by an aperture. Hollow cylindrical chassis 2
The other end of the shaft 9 has a shaft through-hole 32, and a fitting portion 34 is formed at the tip of the shaft through-hole 32 to form a bearing in order to prevent contact with the shaft 33. A cylindrical magnet 35 is attached to the outer peripheral portion of the shaft through hole 32 of the hollow cylindrical chassis 29, and a bearing holder 36 positioned by the end surface of the magnet 35 and the fitting portion 34 is placed on the end surface side of the hollow cylindrical chassis 29. Make up. The sintered metal 37 is inserted into the bearing holder 36, and the shaft 33 is supported at both ends. There are several washers 38, 39 on the end faces of the two sintered metals 31, 37, which receive an axial load.

The commutator hub 40 is fixed to the shaft 33, and the cylindrical winding 41 described in the above embodiment is attached to the outer periphery of the commutator hub 40. The terminal of the winding 41 is electrically connected to the electrode of the commutator hub 40.

A cylindrical frame 42 is mounted on the outer periphery of the hollow cylindrical chassis 29, and a brush holder 43 is attached to an end face of the cylindrical frame 42.
The brush holder 43 has a brush 44, and the tip of the brush 44 is slidably in contact with a commutator 45. A lead wire 46 is connected to the other end of the brush 44. By applying a DC voltage to the lead wire, a current flows through the winding 41, and a rotational force is generated in the winding 41 in relation to the magnet 35 attached to the shaft through-hole 32. Rotate.

At the tip of the shaft 33, a weight 47 is attached to the shaft 33. Vibration can be generated by the weight 47. It is used as a motor for generating vibration of portable terminal equipment.

According to FIG. 9, from the inside of the shaft 33 at the center, the air gap, the shaft through hole 32, the magnet 35, the air gap, the winding 41, the air gap, the cylindrical frame 42, etc. Configuration. That is, it has a configuration of a coreless motor.

Here, a method of determining the basic number of turns of the winding and a method of setting the distance of the mandrel will be described. Although there are various winding specifications, the design method is different, but it is assumed that a basic two-pole magnet and three-phase winding are used.

The dimensions of the winding determined in designing the winding of the motor are the coil length Lc, the coil outer diameter Do, and the coil inner diameter Di. From the inner diameter Di and the outer diameter Do of the coil, the average diameter Dm of the coil is given by the following equation.

[0088]

(Equation 7)

Assuming that the winding is wound around the circumference determined by the average diameter Dm of the coil, the circumference Lm is given by the following equation.

[0090]

(Equation 8)

Therefore, in the case of three phases, the number of turns φs of each phase
Is

[0092]

(Equation 9)

## EQU10 ##

In practice, the winding is adjusted while varying the traverse amount pitch of the winding and the wire diameter used.

When the inner and outer diameters of the coil are determined, the opening width b of the mandrel can be determined. The opening width b of the mandrel is the circumference L
If m is assumed to be 360 degrees, it is equivalent to 180 degrees. That is, it is expressed by the following equation.

[0096]

(Equation 10)

The mandrel distance e is determined from the winding length Lc required in the design. Assuming that the length of the inclined portion does not change when the winding is flat-pressed, the mandrel distance is made equal to the coil length Lc, and the winding is temporarily manufactured.

When there is no regulated press, the total width Lp of the flat-pressed winding is often not the coil length Lc.
It is necessary to subtract the value of (Lp-Lc) from the width of the parallel portion of the winding. The distance of the mandrel is shortened by (Lp-Lc), the winding is manufactured, and the total width Lp of the winding is equal to the coil length. Lc
Repeat the adjustment until equal to

In the same way, in the case of the regulated press, the adjustment is performed until the total width Lp of the winding becomes equal to the coil length Lc. In the case of the regulated press, however, the adjustment is also related to the distance of the wall guide of the regulated press. Therefore, if Lc is determined from the relational expression of (Equation 4), the distance h of the wall guide is set to the following relation.

[0100]

[Equation 11]

With the distance h of the wall guide in the above relationship, the windings are manufactured and the dimensions of the respective parts are adjusted so that the windings of the design dimensions can be formed. Since the characteristics of the motor depend on the target resistance value and the usable winding wire diameter,
The specifications of the motor are determined based on (Equation 11).

The opening angle a of the mandrel is not determined from the dimensions of the winding, but is determined by experience in stably manufacturing the winding of the motor. Problems in the determination will be described later.

FIG. 10 is a schematic view of a flat forming coil that has been flat pressed. FIG. 10A is an entity schematic diagram representing the entity so that each winding can be understood one by one.
Temporary fixing tape is stuck. FIG. 10 (b) is a schematic diagram showing a shape such as a phase of a winding and a terminal portion. Figure 1
At 0, 48 and 49 are hexagonal portions, and the hexagonal portion of 49 is not directly seen from above the paper surface by the upper coil, so that the hexagonal portions are represented by broken lines. 50 is a parallel portion, 50a is a parallel portion of the lower coil, 50b is a parallel portion of the upper coil, 51 is a slope portion, 51a is a slope portion of the lower coil, and 51b is a slope portion of the upper coil. Parallel part 50
Corresponds to the parallel portion of the hexagonal winding wound in a line. Since the alignment is performed before the pressing, the parallel portions 50 after the pressing are also aligned. The parallel portion 50a of the lower coil has a single-layer winding arrangement, and the parallel portion 50b of the upper coil also has a single-layer winding arrangement. When the flat press forming coil as shown in FIG.
And the hexagonal portion 49 in order to overlap with the cylindrical shape of the winding,
The winding of the parallel portion 50 is located anywhere on the parallel portion 5 of the upper coil.
0b and the parallel portion 50a of the lower coil exist, and the parallel portion 50 becomes a winding having a uniform thickness. Since the windings are wound so that the winding length f at the time of winding is aligned, the parallel portions of the windings are arranged in a winding arrangement, and the winding length is set to the average circumferential length Lm of the windings. f are equal.

FIG. 10 shows the angle when the cylindrical shape is formed. For example, the angle of the hexagon 48 is 18
This corresponds to 0 degrees, and the angle between the terminal portions is 120 degrees.

FIG. 11 is a schematic diagram of a winding of a parallel portion of a flat forming coil. Length f of parallel part of upper and lower coil
3 is the number of turns φ of the coil having the total wire diameter Dc as shown in FIG.
If they are aligned with

[0106]

(Equation 12)

The relationship is as follows. The length of the flat forming coil is determined by the winding length f, and since the winding state is a single-layer alignment state, the single-layer alignment state is maintained even when flat pressing is performed. The length f3 of the parallel portion of the upper and lower coils is equal to the winding length f.

FIG. 12 is a schematic view of a gradient coil. As shown in the schematic diagram of FIG. 12, the total wire diameter Dc of the coil is aligned with the number of turns φ in the parallel portion where the coil is not inclined, so that the coil is represented by a length f4 arranged in the horizontal direction. Assuming that the coil is inclined and the inclined portion is in a single layer state, the coil exists up to a position drawn by an arc of radius f4 (indicated by a broken line). It exists only in the range of the part distance f5. Assuming that the inclination angle of the inclined portion is the opening angle, the inclination angle of the inclined portion is (α / 2) from the opening angle α of the inclined portion.

When the relationship between the length f4 aligned in the horizontal direction and the slope distance f5 is expressed using the slope angle (α / 2) of the slope, the following equation is obtained.

[0110]

(Equation 13)

Is as follows.

The length f4 aligned in the horizontal direction is f4 = f
3, the windings at the time of the inclination are arranged in an aligned manner. Therefore, f5 <f obtained from (Equation 13)
From the relationship of 4, it is presumed that the windings of the inclined portion are not aligned.

From Expression (13), the fact that the relationship of f5 <f4 is obtained is presumed that the inclined portion is in a different state. It is considered that the inclined portion is not in a single layer state but in a state of one or more layers. From (Equation 13),

[0114]

[Equation 14]

In the modification as described above, the value of (f4 / f5) is related to the number of layers of the winding. FIG. 13 shows the relationship of (Equation 14). If (f4 / f5) is larger than 1, it is not a one-layer state, and if the lamination state is regular, (f4 / f5)
The rounded-up integer value of 5) is considered to be the number of layers.
From FIG. 13, when the inclination part opening angle α is equal to or less than 120 degrees, 1 <
Since (f4 / f5) ≦ 2, the number of layers is 2. However, when the angle exceeds 120 degrees, the number of layers greatly differs depending on the angle. For example, the number of layers is 3 when the opening angle α is 130 degrees, the number of layers is 4 when the opening angle α is 150 degrees, and the number of layers is 160 when the opening angle α is 160 degrees. It will be 6. When the inclination angle α is 180 degrees, the number of layers becomes infinite. When it is considered that the opening angle α of the inclined portion is 180 degrees and the opening angle a of the mandrel is equivalent to 180 degrees, when the opening angle a of the mandrel is 180 degrees, (f4 / f5) becomes infinity. The angle of 180 degrees cannot be actually used as it is. Therefore, the opening angle a of the mandrel is set to 170 degrees or less.

Therefore, by setting the opening angle of the mandrel in the embodiment to 121 degrees or more, the length of the parallel portion of the winding is increased, and the motor characteristics are improved. When the opening angle a of the mandrel is 120 degrees, the length of the parallel portion and the length of the inclined portion are wound the same, but when the angle is 121 degrees or more, the length of the parallel portion is longer than the length of the inclined portion. Mandrel opening angle is 120
The larger the degree, the longer the parallel portion. The opening angle of the mandrel is 121 degrees or more, the number of layers is increased, and the length of the parallel portion is increased. In the present invention, the length of the linear conductor portion in the cylindrical axis direction can be increased, and the winding portion of the inclined portion can be increased. , The coreless motor having excellent motor characteristics can be obtained. By using the regulating press together, the extension of the length of the inclined portion is reduced, so that a winding length close to the mandrel distance can be obtained. Therefore, the opening angle a of the mandrel is set to be not less than 121 degrees and not more than 170 degrees.

The opening angle α of the inclined portion is changed by the flat press, so that the length of the inclined portion changes.
Is not the same as the opening angle α of the inclined portion, but does not match because the length of the inclined portion changes, so it can be said that the value is related to the opening angle a of the mandrel. When the opening angle α of the inclined portion is not known, the opening angle a of the mandrel is regarded as the opening angle α of the inclined portion, and the design of the winding is performed. The relationship between the opening angle a of the mandrel and the opening angle α of the inclined portion will be described later based on experimental results.

When the inner diameter Di of the coil, the mandrel opening angle a, and the total coil diameter Dc are determined, the outer diameter D of the coil is determined.
In order to obtain o and the number of winding turns φ, first, the mandrel opening angle a
(For example, when a = 130 degrees, n = 2, from FIG. 13). At that time, the coil outer diameter Do
Is represented by the following equation. However, considering that the outer diameter of the winding is the outer diameter of the coil at the point where the thickness of the winding becomes thicker,
The outer diameter of the coil at the inclined portion is defined as the outer diameter Do of the coil.

[0119]

(Equation 15)

The factor 4 in the above equation is considered as follows. Depending on the press, there are an upper coil and a lower coil, which are multiplied by a factor of 2 times, that is, 4 times, because of the diameter. When a = 130 degrees, n = 2.
5) is Do = Di + 8 · Dc.

Therefore, the average diameter Dm is

[0122]

(Equation 16)

The outer peripheral length Lm of the average diameter Dm is

[0124]

[Equation 17]

And the total number of turns φ is

[0126]

(Equation 18)

Is obtained.

The thickness of the winding in the parallel portion of the flat forming press coil is 2Dc which is twice the total meridian Dc of the winding, but the thickness of the inclined portion is 2nDc. In the case of n = 2, the thickness is 4Dc, so the inclined portion becomes thicker by 2Dc. Depending on the opening angle a of the mandrel, the increase in the thickness of the inclined portion differs, and becomes 6Dc at a = 150 degrees.

The opening angle a of the mandrel and the opening angle α of the inclined portion
The relationship will be described based on the experimental results.

First, the opening angle α of the inclined portion of the press forming coil in which the winding having the opening angle a of the mandrel was a flat press only was measured.

FIG. 14 shows the relationship between the opening angle a of the mandrel and the opening angle α of the inclined portion. Since the winding having the opening angle a of the mandrel is flat-pressed, the opening angle α of the inclined portion necessarily increases as the opening angle a of the mandrel increases. If there is no change in the slope width, a = α. However, as described above, the slope width actually changes. In FIG. 14, a =
Although the line related to α is drawn by a dashed line, the measurement point is located below the dashed line, and therefore, if flat pressing is performed, the opening angle α of the inclined portion is smaller than the opening angle a of the mandrel. Therefore, it is understood that the width of the inclined portion of the winding is longer by flat pressing than before pressing.

FIG. 15 shows the relationship between the opening angle a of the mandrel and the angle change amount obtained by subtracting the opening angle α of the inclined portion from the opening angle a of the mandrel in order to represent the amount of change in the opening angle of the inclined portion with respect to the opening angle a of the mandrel.

FIG. 15 shows that the opening angle a of the mandrel is a = 120.
In the case of degrees, the opening angle a of the mandrel from the opening angle α of the inclined part
Is the smallest angle change amount. That is, when the opening angle a of the mandrel is 120 degrees, the opening angle α of the inclination angle is 12
It will be close to 0 degrees. From the relationship between the opening angle α of the inclined portion and (f4 / f5) in FIG.
At 0 degree, (f4 / f5) = 2 and α is 120
In the case of degrees or less, since (f4 / f5) ≦ 2, it is considered that the tendency does not change even if the opening angle α of the inclined portion is replaced with the opening angle a of the mandrel. That is, (f4 / f5) ≦ 2 when the opening angle a of the mandrel is 120 degrees or less, and (ff) when the opening angle a of the mandrel is 120 degrees or more.
4 / f5)> 2. (F4 / f5) = 2 has a special meaning. When the opening angle a of the mandrel is 120 degrees, it is considered that the angle change amount obtained by subtracting the opening angle α of the inclined portion from the opening angle a of the mandrel becomes the smallest, which has a special meaning in terms of shape.

When laminating windings having a round cross section, there are two regular lamination shapes as shown in FIG. The two laminated shapes will be examined.

Since the total number of windings is φ, the total number of windings is also φ. For calculation, φ is an even number. The total wire diameter of the winding is Dc. First, in the case of vertical stacking in FIG. 16A, the number of upper windings is φ / 2, the number of lower windings is φ / 2, and the lamination width of the windings is (Dc · φ / 2). Become. Also in the case of the bale stacking of FIG. 16 (b), although the height of the lamination is different, the number of lower windings is φ / 2 and the number of upper windings is φ / 2. The width is (Dc · φ / 2).

As shown in FIG. 12, in the parallel portion, the winding is formed so that the winding in one row is not a single layer in the inclined portion, so that the winding state of the inclined portion is shown in FIG. Considering that the layers are stacked vertically, from (Equation 12),
The opening angle α of the inclined portion in that state can be obtained. This will be described with reference to FIG. The parallel portion has a length s1 in a single-row winding state, and the winding distance s2 of the inclined portion is the distance of the winding perpendicular to the inclined portion. If the slope is angle β1,

[0137]

[Equation 19]

There is the following relationship. The parallel portion is in a single-row winding state, and the length s1 is s1 = (Dc · φ). Considering that the inclined portion is in a vertically stacked state, the lamination width of the winding is (Dc · Φ / 2), so s2 = (Dc · φ
/ 2). Therefore, by substituting into (Equation 19),

[0139]

(Equation 20)

Is as follows. That is, β1 = 60 degrees.
As shown in FIG. 17, when the inclined portions are vertically stacked, the opening angle of the inclined portions is 120 degrees (from α = 2 · β1).
It is one state of the winding state of the singularity of α = 120 degrees shown in FIG.

The case where the stacked state of the inclined portion is a bale stack will also be described with reference to FIG.

S3 is the length in the state of one row of windings of the parallel portion, and s4 is the distance of the winding perpendicular to the inclined portion, that is, the winding distance of the inclined portion. If the slope is angle β2,

[0143]

(Equation 21)

There is the following relationship. The length of the parallel portion is s3 from the total wire diameter Dc and the total number of turns φ.
= (Dc · φ). Assuming that the inclined part is in a stacked state of bale stacking, the winding is shifted in lamination,
Since the distance s4 is larger than the wire diameter, the lamination width of the winding is (Dc · φ / 2).
Is expressed by s4 = (Dcφ / 2). Therefore,
Substituting into (Equation 21),

[0145]

(Equation 22)

Is obtained. That is, the inclination angle β2 is β1
Similarly, β2 = 60 degrees. As shown in FIG. 18, when the inclined portion is in a stacked state of bale stacking, the opening angle of the inclined portion is 120
Degree (from α = 2 · β2). This case is also considered to be one of the winding states of the specificity of α = 120 degrees shown in FIG.

Since the inclination angles β1 and β2 are (１ ／) of the opening angle α of the inclined portion of the winding, when stacking vertically or in a bale, the opening angle of the inclined portion is 120 degrees. is there.

Although the shapes can be stacked vertically or stacked in a bale, it is more appropriate to consider that the inclined portion is stacked in a bale, considering which one can maintain the shape stably.

Next, as in the case of (f4 / f3) = 2, it is considered that the windings are laminated in a regular lamination into a four-stage shape where (f4 / f3) = 4. For example, FIG.
The opening angle α of the inclined portion from (3) to (f4 / f3) = 4 = 1
50 degrees. Therefore, the opening angle a of the mandrel is 1
Some difference should appear in the angle change amount obtained by subtracting the opening angle a of the mandrel from the opening angle α of the inclined portion near 50 degrees. 14 and 15, it can be seen that the lines of the graph rise when the opening angle a of the mandrel is 150 degrees and 160 degrees. That is, when the opening angle a of the mandrel is 150 degrees or 160 degrees, the ratio of the angle change amount obtained by subtracting the opening angle α of the inclined portion from the opening angle a of the mandrel is relatively small as compared with the vicinity. This climax is a =
It is not as prominent as at 120 degrees, but has a similar form.

A description will be given of the turning of the inclined portion represented by the opening angle of the inclined portion. The winding of the parallel portion is in a layered state at the inclined portion, but at the folded portion of the inclined portion, the winding is connected from the upper winding to the lower winding and is in a layered state. Therefore, the winding moves at the time of pressing so that the state of the winding near the ridgeline of the turn-back is as shown in FIG. When the conceptual schematic diagram of FIG. 19 is represented by a cross section of a winding, it is like a bale stack. FIG. 19 is an explanatory diagram of the winding at the vertex position of the return of the inclined portion. As shown in FIG. 19, the positions of the vertices of the turn of the inclined portion are not aligned on the same straight line. Actually, the windings appear to be separated, but as shown in FIG. 19, the windings become forming coils so as to be divided into two groups.

[0151]

As is clear from the description of the above embodiment,
According to the first aspect of the present invention, the length of the straight conductor portion in the cylindrical axis direction in the hexa winding can be increased while the specification of the winding is determined, and the ratio of the length of the winding portion of the inclined portion is reduced. This has the advantageous effect of being able to do so.

According to the second aspect of the present invention, the length of the linear conductor in the cylinder axis direction in the hexa winding can be increased,
Since the ratio of the length occupied by the winding portion of the inclined portion can be reduced, an advantageous effect that the motor characteristics can be improved while the size is determined is obtained.

According to the third aspect of the present invention, the mandrel interval can be adjusted by changing the gap of the split type mandrel, and the gap is reduced to zero for the split mandrel. It can be obtained that the mandrel can be easily removed from the mandrel while maintaining the wound shape of the winding.

According to the fourth aspect of the present invention, the mandrel interval can be adjusted by changing the gap of the split type mandrel, and the gap is reduced to zero for the split mandrel. The winding can be easily removed from the mandrel while maintaining the winding shape by adjusting the mandrel to, and there is no tapered mandrel for easy removal Can be used to produce a corel motor.

According to the fifth aspect of the present invention, by using the split type mandrel, the mandrel interval can be easily adjusted, and the mandrel width of the split mandrel can be adjusted by the electric force of the armature. It is said that a relatively long mandrel width can be secured because the length is equivalent to the angle of 180 degrees, and that the parallel portion can be lengthened because the opening angle of the mandrel can be increased, so that a winding having good motor characteristics can be obtained. It is effective.

According to the sixth aspect of the present invention, by using the split type mandrel, the mandrel interval can be easily adjusted, and the mandrel width of the split mandrel can be adjusted by the electric force of the armature. Since the length is defined as the angle corresponding to the angle of 180 degrees, a relatively long width of the mandrel can be secured, and since the opening angle of the mandrel can be increased, the parallel portion can be lengthened, and a coreless motor having good motor characteristics can be obtained.

According to the seventh aspect of the present invention, the length of the linear conductor in the cylindrical axis direction can be increased, and the ratio of the length occupied by the winding portion of the inclined portion can be reduced. In addition to the coreless motor with excellent performance, the length of the inclined part is reduced by controlling the pressure.
A mandrel with a winding length close to the mandrel distance can be made, and once the winding length is determined, the mandrel can be designed in a short time.

According to the eighth aspect of the present invention, the length of the linear conductor in the cylindrical axis direction can be increased, and the ratio of the length occupied by the winding portion of the inclined portion can be reduced. In addition to the excellent winding of the mandrel, the length of the slanted part can be reduced by applying the regulation press, so the winding length can be made close to the mandrel distance. This has the advantageous effect that the design can be performed in a short time.

Further, according to the ninth aspect of the present invention, the terminal portion is not regulated and pressed by storing and pressing the terminal portion in the cut portion. Pressing in a state in which the terminal part that has no cut-out part is folded is likely to cause the wire and the terminal part to be broken, and there is a risk of damaging the terminal part when the pressed terminal part is removed after pressing Is obtained.

According to the tenth aspect of the present invention,
The terminal portion is not regulated and pressed by storing and pressing the terminal portion in the cut portion. Pressing in a state in which the terminal part that has no cut-out part is folded is likely to cause the wire and the terminal part to be broken, and there is a risk of damaging the terminal part when the pressed terminal part is removed after pressing There is no.

According to the eleventh aspect of the present invention,
The thickness of the flat press forming coil, which corresponds to the corner of the regulating press, can be pressed to a predetermined thickness, and the terminal is also pressed to achieve the predetermined thickness. Motors are possible.

[Brief description of the drawings]

FIG. 1 is a mandrel diagram of a split type winding device in an embodiment of the present invention. (A) Front view (b) Top view (c) Left view

FIG. 2 is a sectional view of a winding-using portion of the split type mandrel of FIG.

FIG. 3 is an explanatory sectional view of the mandrel when two of the split type mandrels shown in FIG. 1 are set in a winding device;

FIG. 4 is a view for explaining a winding process using a two-part type mandrel;

FIG. 5 is an explanatory view showing a state in which a winding wound around a mandrel is temporarily fixed with a tape;

FIG. 6 is a regulation guide diagram of a regulation guide press process according to an embodiment of the present invention.

FIG. 7 is a regulation guide diagram with a cut portion formed according to an embodiment of the present invention.

FIG. 8 is a model diagram of a locus of a winding in which a winding height becomes zero in a pressing process.

FIG. 9 is a sectional view of a coreless motor according to an embodiment of the present invention.

FIG. 10 is a schematic diagram of a flat-formed coil formed by flat pressing. (A) Schematic diagram of the actual body.

FIG. 11 is a schematic view of a winding of a parallel portion of a flat forming coil.

FIG. 12 is a schematic view of a gradient coil.

FIG. 13 is a diagram showing the relationship between the opening angle of the inclined portion and (f4 / f5).

FIG. 14 is a diagram showing the relationship between the opening angle of the mandrel and the opening angle of the inclined portion.

FIG. 15 is a diagram illustrating a change amount of the opening angle of the inclined portion with respect to the opening angle of the mandrel.

FIG. 16 is a diagram showing a regular lamination shape when laminating windings having a round cross-section; FIG. 16A is a diagram showing vertical stacking; FIG.

FIG. 17 is an explanatory view of a stacked state in which an inclined portion is vertically stacked.

FIG. 18 is an explanatory view of a stacked state in which the inclined portion has a bale stack

FIG. 19 is an explanatory diagram of a winding at a vertex position of a turn of an inclined portion.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mandrel 2, 51 Inclined part 3 First phase winding part 4 Second phase winding part 5 Third phase winding part 6, 7, 8, 9, 28, 28a, 28a, 28b Terminal part 10 Winding Winding start end 11 Winding start temporary winding section 12 Winding winding end end 13 Temporary winding section at end of winding 14 Tape (temporary fixing tape) 15, 16 Surface to which tape is applied 17 Regulatory guide 18 Regulatory support tray 19, 20 Wall Guide 21 Punch of regulating guide 22 Convex part of punch 23 Concave part 24, 26, 26a, 26b, 27, 41 Winding 25, 25a, 25b, 25c, 25d Cut part 29 Hollow cylindrical chassis 30 Concave part 31, 37 Sintered metal 32 Shaft through hole 33 Shaft 34 Fitting part 35 Magnet 36 Bearing holder 38, 39 Washer 40 Commutator hub 42 Frame 43 Brush holder 44 Brush 4 Commutator 46 Lead wire 47 Weight 48, 49 Hexagonal portion 50 Parallel portion 50a Parallel portion of lower coil 50b Parallel portion of upper coil 51a Inclined portion of lower coil 51b Inclined portion of upper coil a Open angle of mandrel b Mandrel Opening width c Thickness of the inclined part of the mandrel d Thickness of the parallel part of the mandrel e Mandrel interval f Winding length f1 Tape length g Gap g1 Tape width h Wall guide distance D Winding diameter f2 Notch Width g2 Curling tape width Di Coil inner diameter Do Coil outer diameter Dm Coil average diameter Lm Circumference Dc Coil total wire diameter dc Coil conductor wire diameter δ Coil film thickness φ Total number of turns φs Number of turns in each phase Lc Coil length Lp Total width of winding Kt Motor torque characteristics f3 Length of coil in aligned state f4 Length aligned in horizontal direction f5 Tilt Opening angle of the part distance α inclined portion

Continued on front page F-term (reference) 5H603 AA03 AA09 BB01 BB04 BB13 CA05 CB01 CB12 CC02 CC19 CD05 CD32 CD33 CE01 EE09 FA18 5H604 AA05 AA08 BB07 BB14 BB15 CC02 CC04 CC12 DB02 DB18 DB19 DB25 QB03 5H615 AA01Q13 BB01 Q01 SS11 SS24 TT28 5H623 AA05 AA10 BB04 BB07 GG16 HH02 HH06 LL09

Claims (14)

[Claims] 1. A hexagonal winding is wound around a winding mandrel, and in a state of being wound around the mandrel, a tape is stuck on two opposing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. In a winding apparatus for extracting an wound winding, flat-pressing the tape so that the tape is up and down, and curling the flat-pressed winding to produce an armature formed into a cylindrical shape, Opening angle of the winding mandrel is 1
A winding device for a mandrel that is not less than 21 degrees and not more than 170 degrees. 2. A hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is stuck on two opposing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. A coreless motor using an armature formed by extracting a wound winding, flat-pressing the tape up and down, curling the flat-pressed flat forming coil, and using a cylindrically-shaped armature. Angle of the winding mandrel is 1
Using a mandrel that is 21 degrees or more and 170 degrees or less,
A coreless motor using an armature characterized in that an opening angle of an inclined portion of a flat press forming coil in a flat press is set to be not less than 121 degrees and not more than 170 degrees. 3. A hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is stuck on two opposing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. A winding device for extracting a wound winding, flat-pressing the tape up and down, curling the flat-pressed forming coil, and manufacturing a cylindrically-shaped armature, wherein the armature is manufactured. 2. The winding device according to claim 1, wherein the winding mandrel is divided into two, and a gap is provided between the two mandrels. 4. A hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is stuck on two facing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. A coreless motor using an armature formed by extracting a wound winding, flat-pressing the tape up and down, curling the flat-pressed flat forming coil, and using a cylindrically-shaped armature. The coreless motor according to claim 2, wherein the winding mandrel for the motor is divided into two, and a gap is provided between the two mandrels. 5. A hexagonal winding is wound around a winding mandrel, and in a state of being wound around the mandrel, a tape is stuck on two opposing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. In a winding apparatus for extracting an wound winding, flat-pressing the tape so that the tape is up and down, and curling the flat-pressed winding to produce an armature formed into a cylindrical shape, Is divided into two, and this mandrel is formed with two inclined surfaces having an angle that determines the opening angle of the winding, and one end of this inclined surface is a parallel portion facing the other mandrel. The winding device according to claim 1, wherein a distance between both ends of the inclined surface is defined to a length corresponding to an electric angle of 180 degrees of the armature. 6. A hexagonal winding is wound around a mandrel for winding, and in a state where the winding is wound around the mandrel, a tape is stuck on two inner surfaces facing each other and temporarily fixed, and then the mandrel is rotated. A coreless motor using an armature formed by extracting a wound winding, flat-pressing the tape up and down, and curling the flat-pressed winding to form a cylindrical armature. The winding mandrel is divided into two, and this mandrel has two inclined surfaces with an angle that determines the opening angle of the winding, and one end of the inclined surface has a parallel portion facing the other mandrel. The coreless motor according to claim 2, wherein the mandrel is configured, and a distance between both ends of the inclined surface is defined to a length corresponding to an electrical angle of 180 degrees of the armature. 7. A hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is stuck on two opposing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. In a winding device for extracting a wound winding, flat-pressing the tape up and down, and manufacturing a cylindrically-shaped armature by curling the flat-pressed winding, in the flat-pressing step, Forming and winding down the wound winding, flat pressing on both sides of the winding in parallel with the flattening direction so that the winding does not spread in the direction perpendicular to the flat direction. Coreless motor using an armature using wires. 8. A hexagonal winding is wound around a mandrel for winding, and in a state where the winding is wound around the mandrel, a tape is stuck on two facing surfaces of the six surfaces and temporarily fixed, and then the mandrel is rotated. In the winding device for extracting the wound winding, flat-pressing the tape up and down, and manufacturing a cylindrically-shaped armature by curling the flat-pressed winding, Forming and winding down the wound winding, flat pressing on both sides of the winding in parallel with the flattening direction so that the winding does not spread in the direction perpendicular to the flat direction. Winding device for manufacturing armatures using wires. 9. In a flat pressing step, the wound windings are formed and fallen so that the windings do not spread in a direction perpendicular to the flat direction on both sides of the windings in parallel with the flattening direction. 9. The armature according to claim 8, wherein the flat pressing device is provided with a cutout for escaping the terminal portion so that the terminal portion of the winding is not restricted by the restriction press. Winding device. 10. In a flat pressing step, the wound winding is formed and turned down so that the winding does not spread on both sides of the winding in a direction perpendicular to the flat direction in parallel with the flattening direction. The apparatus according to claim 7, wherein a notch for escaping the terminal is provided on the terminal of the winding so that the terminal of the winding is not restricted by the restricting press. Coreless motor using armature. 11. A hexagonal winding is wound around a mandrel for winding, and in a state of being wound around the mandrel, a tape is stuck on two inner surfaces facing each other and temporarily fixed to the mandrel. In a coreless motor using an armature formed by extracting a wound winding, flat pressing the tape up and down, curling the flat pressed forming coil, and using a cylindrically formed armature, the flat pressing step Then, form and wind the wound coil, flatten it on both sides of the winding in parallel with the direction of flattening so that the winding does not spread in the direction perpendicular to the flat direction, A coreless motor using an armature that uses a flat press forming coil by flat pressing again with a pressing device without any restriction in the width direction in order to form wire terminal portions. 12. An OA device using the coreless motor according to any one of claim 2, claim 4, claim 6, or claim 7, or claim 10, or claim 11. 13. A medical device using the coreless motor according to any one of claim 2, claim 4, claim 6, or claim 7, or claim 10, or claim 11. 14. A communication terminal using the coreless motor according to any one of claim 2, claim 4, claim 6, or claim 7, or claim 10, or claim 11.