JP2004080860A - Motor component and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a motor component which can enhance the space factor and to provide its manufacturing method. <P>SOLUTION: This motor component has a core and a plurality of coils 10, which are formed continuous by winding a lead wire on the core. The core is equipped with a ring part and a projection which elongates in the radial direction of the ring part and on which the lead wire is wound. The coil has a straight part 11 and a crooked part 12. The lead wire sectional form of the straight part is rectangular, and the lead wire sectional form of the crooked part is trapezoidal form, with its thickness on the peripheral side of the bend being smaller than that on the inner perimeter side. Then, among two or more coils, the coils of the same phase are coupled with each other via the bend being made by bending the above lead wire, and the sectional form of the bend 80 is trapezoid, with its thickness on the peripheral side of the bend smaller than that on internal perimeter side. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a motor component and a method for manufacturing the same. In particular, the present invention relates to a motor component capable of realizing a high space factor and a method for manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art In a conventional motor, a rotor or a stator having a core provided with a coil is widely known. Generally, a rotor or a stator includes a ring portion and a plurality of protrusions extending in a radial direction of the ring portion. The coil is formed by winding a conductive wire around each of the protrusions to obtain a required number of ampere turns. In addition, a wire having a round or square cross section was used for this conductive wire.
[0003]
[Problems to be solved by the invention]
However, when such a conductor is used, a gap is generated between the conductors, and the space factor (the ratio of the conductor area in the cross section of the coil arrangement space) cannot be increased. In particular, there has been a demand for a means capable of improving the space factor and easily manufacturing a plurality of continuous coils.
[0004]
Usually, the conductor is coated with an insulating material such as an enamel resin. However, this insulating coating hinders the dissipation of generated heat when the motor is driven. If a small-diameter wire is used, the number of stacked wires in the circumferential direction of the ring (the circumferential direction of the motor rotation shaft) increases, and as a result, the number of stacked insulating coatings also increases, lowering the heat dissipation efficiency and reducing the heat dissipation inside the motor. The increase in temperature caused a further decrease in efficiency.
[0005]
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a motor component in which a plurality of coils are continuously formed and a space factor can be easily increased.
[0006]
It is another object of the present invention to provide a method for manufacturing a motor component that is optimal for forming the motor component.
[0007]
[Means for Solving the Problems]
In the present invention, the above object is achieved by using a conductive wire having a rectangular plate-like cross section for the coil and devising a manner of bending the conductive wire.
[0008]
That is, the motor component of the present invention is a motor component having a core and a plurality of coils formed continuously by winding a conductive wire around the core. The core includes a ring portion and a protrusion extending in a radial direction of the ring portion and around which the conductive wire is wound. The coil has a straight portion and a bent portion. The cross-sectional shape of the straight portion is a rectangular plate, and the cross-sectional shape of the bent portion is a trapezoid in which the thickness on the outer peripheral side of the bend is smaller than the thickness on the inner peripheral side. And, among the plurality of coils, the coils of the same phase are connected to each other via a bent portion obtained by bending the conductive wire, and the cross-sectional shape of the bent portion is such that the thickness on the outer peripheral side of the bend is smaller than the thickness on the inner peripheral side. It has a trapezoidal shape.
[0009]
Further, a method of manufacturing a motor component according to the present invention includes the following steps.
{Circle around (1)} A linear wire with a rectangular cross section formed by rolling is conveyed linearly to form a linear portion, and one of the side edges of the wire is intermittently rolled to be larger than the other. Forming a coil having a trapezoidal cross section to form a coil composed of a straight portion and a bent portion. (2) After forming the coil, one side edge of the conductive wire is intermittently connected to the other side edge. (3) a step of forming a bent portion having a trapezoidal cross section continuously at the coil end portion after forming the bent portion, so that one side edge side of the conductive wire is intermittently shifted to the other side edge side. A step of forming a bent portion having a trapezoidal cross-section by rolling to a greater extent and continuously forming another coil composed of a straight portion and a bent portion; (4) a step of fitting projections inside each coil; [0010]
As described above, by rolling the rectangular plate-shaped conductive wire intermittently with different crushing degrees in the width direction, it is possible to manufacture a coil in which the bent portion and the linear portion are continuous.
[0011]
The use of a rectangular plate-shaped conductor eliminates the lamination of the conductor in the radial direction of the ring, that is, the circumferential direction of the motor rotation shaft, and forms a single layer to obtain a motor component having a high space factor and a high heat dissipation effect. be able to.
[0012]
The trapezoidal cross section of the conductor has a tendency to have a smaller cross sectional area than the rectangular flat plate cross section, and therefore has relatively high electrical resistance and a low space factor, which is disadvantageous also on the heat radiation surface. Therefore, the bent portion having a trapezoidal cross section of the conductive wire is provided as short as possible on the end face side of the ring portion (the end face side in the motor axial direction). With this configuration, it is possible to minimize the length of the portion having relatively high electric resistance and large heat generation, to avoid large heat generation, and to arrange the large heat generation portion on the end face in the motor axial direction which is advantageous for heat radiation.
[0013]
On the other hand, the straight portion composed of the conductive wire having a rectangular flat plate cross section is arranged in the space formed between the projections, but is in contact with the projections over a wide range, so that efficient heat conduction is achieved. High heat dissipation can be expected.
[0014]
The conducting wire portion having a rectangular flat cross section can be obtained by rolling the material to be rolled between a pair of cylindrical rollers as in the conventional case. A conducting wire portion having a trapezoidal cross section can be obtained by intermittently passing a conducting wire of a rectangular flat plate between a pair of conical rollers. Then, by rolling the conical roller intermittently after the rolling by the cylindrical roller, a coil having a continuous bent portion and a straight portion can be obtained. That is, when a rectangular flat conductive wire sent through a cylindrical roller is passed through a conical rolling roller, one side edge of the conductive wire is crushed more than the other side edge. Therefore, one side edge side of the conductive wire will be greatly extended in the longitudinal direction as compared with the other side edge side, and the conductive wire will be bent with the side edge side with a small crush degree as the inner circumference and the side edge side with a large crush degree with the outer circumference. Will be. Therefore, if the rolling by the conical roller is performed while the interval between the conical rollers is intermittently closed for a predetermined time, a coil having a straight portion and a bent portion can be manufactured using a conductive wire having a rectangular flat plate cross section. The bending radius of the bent portion can be adjusted by changing the difference between the diameter of one end and the other end of the conical roller, thereby changing the degree of crushing of one side edge of the conductor and the other side edge.
[0015]
Furthermore, if the coil is a plurality of coils used in a multi-phase motor, the coil of the same phase may form a bent portion by the same method as the method of forming the bent portion, and the plurality of coils may be formed continuously. it can. The cross-sectional shape of the bent portion is also a trapezoidal shape in which the thickness on the outer peripheral side of the bend is smaller than the thickness on the inner peripheral side.
[0016]
That is, after one coil is formed by the above-described rolling, the next coil is formed continuously using the same conductive wire. At this time, if the bent portion connecting the plurality of coils is formed between the coils by rolling the outer circumference of the conductive wire larger than the inner circumference and making it thinner, it is easy to continuously form the plurality of coils. it can.
[0017]
In the step of fitting the core inside the coil, it is preferable that the projecting portion and the ring portion of the core are configured to be splittable. Usually, since the tip of the projection is wider than the ring side, the coil cannot be fitted from the tip of the projection. Therefore, if the projection is configured to be detachable from the ring, once the projection is removed from the ring, the coil is fitted, and then the projection is fixed to the ring, thereby configuring the rotor or the stator. can do.
[0018]
Further, it is preferable that the conductive wire is configured to be wider and thinner from the inner peripheral side toward the outer peripheral side with the rotation axis of the motor as a center. In the core, the space formed between the protrusions and in which the conductive wire is arranged has a circumferential length longer on the outer circumferential side in the ring portion radial direction than on the inner circumferential side. For this reason, the coil portion arranged in the outer peripheral region of the core has a wider width of the conducting wire than the coil portion arranged in the inner peripheral region, so that the space for disposing the coil has a different width at the inner and outer periphery of the ring portion. Even in this case, the space factor can be increased.
[0019]
As described above, in order to form a thin conductor on the inner peripheral side and a thin conductor on the outer peripheral side, when rolling the conductor, the rolling reduction is continuously increased when the conductor is rolled, and the conductor is rolled from the beginning. The end forms a thinner conductor. Subsequently, one side edge side of the conductive wire may be intermittently rolled larger than the other side edge side to form a bent portion having a trapezoidal cross section.
[0020]
The motor component as described above can be used as a rotor or a stator of the motor. Generally, the rotor includes a ring portion and a plurality of protrusions radially formed from the ring portion toward the outer periphery. The stator includes a ring portion and a plurality of protrusions projecting toward the center. In either case, the conductor is wound around the outer periphery of the projection to form a coil. In general, the projection often has a rectangular cross section that is long in the motor axis direction.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described.
(Basic configuration of coil)
Before describing a plurality of continuous coils, a single coil constituting the motor component of the present invention will be described. 1A is a perspective view of a coil used for a motor component, FIG. 1B is a cross-sectional view of a part X in FIG. 1A, and FIG. 1C is a cross-sectional view of a part Y in FIG.
[0022]
As shown in FIG. 1, the coil 10 is formed by spirally winding the conductive wire 1 and includes a straight portion 11 in which the conductive wire 1 extends linearly, and a bent portion 12 in which the conductive wire 1 is bent. . The straight portion 11 is formed of a conductive wire having a rectangular flat plate in cross section (FIG. 1C), and the bent portion 12 is formed in a substantially trapezoidal shape in which one side in the width direction of the wire is smaller in thickness than the other side. . In the bent portion 12, the side edge with a small thickness is located on the outer peripheral side of the coil.
[0023]
In such a coil, as shown in FIG. 2, first, a material to be rolled is passed through a pair of cylindrical rollers 20 to form a conducting wire having a rectangular flat plate cross section. Subsequently, the conductive wire sent through the cylindrical roller 20 is intermittently rolled using the conical roller 21. Here, among the conductor side edges, the conical roller 21 is arranged so as to crush only a part in the width direction from the side edge corresponding to the outer periphery of the coil. The portion rolled by the conical roller 21 is reduced in thickness and elongated in the longitudinal direction, so that the conductive wire is bent with the side rolled by the conical roller 21 as the outer periphery. If the conical roller 21 is opened and closed to roll the conductor intermittently, a coil having a linear portion having a rectangular flat plate cross section and a bent portion having a trapezoidal cross section can be obtained. According to the above-described method, the rectangular flat conductive wire can be bent without causing a thick portion or wrinkles on the inner peripheral side of the bent portion. Then, an insulating coating 2 (FIG. 1) such as enamel or ceramics may be applied to the obtained coil.
[0024]
Such a coil is incorporated into a core to form a stator. FIG. 3 is a schematic configuration diagram of a general motor.
[0025]
The inner rotor type brushless DC motor shown in FIG. 3 has a magnet that becomes the rotor 30 on the center side and a stator 40 on the outer periphery. The stator 40 has a core including a ring portion 41 arranged coaxially with the rotor and a plurality of protrusions 42 projecting from the ring portion 41 toward the center. Each of the protrusions 42 has a substantially T-shaped cross section when the motor is viewed from the axial direction, and a coil is formed by winding a conductive wire around its outer periphery. Usually, an insulating material (not shown) is interposed between the coil 10 and the protrusion 42. In this motor, the rotational position of the magnet is detected by using the Hall element 50 and fed back to the inverter 51 to control the energization of the coil 10.
[0026]
FIG. 4 is a partial perspective view showing a state where the coil 10 of FIG. 1 is mounted on such a stator 40. Arrows in the vertical direction in FIG. 4 indicate the motor rotation axis. As shown in this figure, the linear portion 11 of the coil is arranged in the space formed between the adjacent protrusions 42, and the bent portion 12 of the coil is formed on the end face of the stator, that is, outside the space. In order to fit the coil into the T-shaped protrusion, the ring 41 and the protrusion 42 may be divided. That is, the stator 40 may be configured by fitting the coil 10 around the outer periphery of the protrusion 42 once removed from the ring 41, and then fixing the protrusion 42 to the ring 41.
[0027]
When the stator is configured as described above, the bent portion 12 has a smaller conductor cross-sectional area than the straight portion 11 and thus easily generates heat. However, efficient heat radiation is achieved by disposing the bent portion 12 outside the space surrounded by the protrusion 42. be able to. Further, the linear portion 11 that is in direct contact with the protrusion 42 can radiate heat by heat conduction through the protrusion 42.
[0028]
In the above description, the method of manufacturing the motor component of the present invention has been described by taking the configuration in which the coil is provided on the stator as an example, but the coil shown in FIG. 1 can also be used for the rotor. For example, as shown in FIG. 5, a core having a substantially T-shaped projection 62 radially protruding from an outer periphery of a ring portion 61 may be used, and the coil 10 shown in FIG. . A magnet serving as a stator 70 is arranged on the outer periphery of the rotor 60. Also in this case, the coil 10 can be easily fitted by forming the T-shaped projection 62 into a split type with the ring portion 61.
[0029]
(Modification of single coil)
In the basic configuration, an example in which a coil having a uniform thickness in the straight portion is used has been described. However, a coil having a wider and thinner conductive wire toward the outer periphery in the radial direction of the ring portion may be used. FIG. 6 is a partial plan view of a stator using a conductive wire having a variable width and thickness. This plan view shows a state viewed from the rotation axis direction of the motor.
[0030]
As shown in FIG. 6, in the coil 10, the conductor on the inner peripheral side of the ring is narrow and thick, and the conductor on the outer peripheral side is wide and thin. The space formed between the projections 42 is formed in a fan shape when viewed from the motor rotation axis direction. For this reason, if a narrow conductive wire is wound around the distal end side (the inner peripheral side of the ring portion) of the protrusion 42 and a wide conductive wire is wound around the base side (the outer peripheral side of the ring portion), the space occupied by the fan is increased. The coil 10 can be stored at the moment.
[0031]
As described above, the formation of the coil 10 having different thicknesses and widths of the conductor wire on the inner peripheral side and the outer peripheral side can be realized by continuously increasing the rolling reduction of the cylindrical roller 20 in FIG. . That is, at the beginning of rolling, the interval between the cylindrical rollers 20 is increased, and the interval between the cylindrical rollers is gradually reduced as the rolling progresses. Thereby, the width of the conducting wire at the time of being introduced into the conical roller 21 can be widened and the thickness can be reduced.
[0032]
(A plurality of continuous coils used in the motor part of the present invention)
A single coil can be manufactured by the method described above, and furthermore, by forming a bent portion by combining non-uniform rolling in the width direction with a conical roller, a series of conductive wires, in a state where a plurality of coils are connected. FIG. 7 that can be formed is an explanatory view showing a state in which a plurality of coils are connected via a bent portion.
[0033]
In-phase coils in a multi-phase motor can be connected in series. Therefore, as shown in FIG. 7, the coils of the same phase are connected to each other via a bent portion 80 obtained by bending a conductive wire.
[0034]
The cross-sectional shape of the bent portion 80 is a trapezoidal shape in which the thickness on the outer circumferential side of the bending is smaller than the thickness on the inner circumferential side. In order to form the bent portion 80, similarly to the case where the bent portion 12 of the coil 10 is formed, the side edge side of the conductive wire which is the outer peripheral side of the bent portion is rolled larger than the side edge side of the conductive wire which is the inner peripheral side thereof. Can be realized by
[0035]
That is, as shown in FIG. 8, the first conical roller 21 is provided downstream of the cylindrical roller 20, and the second conical roller 22 is further provided downstream. The first conical roller 21 has a roller structure that greatly crushes one side edge of the conductor, while the second conical roller 22 has a roller structure that greatly crushes the other side edge of the conductor. ing.
[0036]
In such a rolling line, a rectangular flat conductive wire is first formed by the cylindrical roller 20. Subsequently, the conductive wire is intermittently rolled by the first conical roller 21 to form a bent portion in which one side edge of the conductor is an outer periphery, thereby producing a coil including a straight portion and a bent portion. Further, when the first coil is manufactured, the other side edge side of the conductor is intermittently crushed by the second conical roller 22 to form a bent portion bent substantially at a right angle. At this time, rolling by the first conical roller 21 is not performed. Then, if the bent portion can be formed, the second coil can be manufactured by performing intermittent rolling again with the first conical roller 21. Of course, by repeating the same process, more coils can be formed continuously. By integrally forming the in-phase coil, not only the coil can be manufactured, but also the coil can be easily incorporated into the protrusion.
[0037]
Also, as shown in FIG. 9, even when the coils 10 of each phase in the multi-phase motor are independently manufactured, the bent portion 80 is formed by using the second conical roller, and the lead wire is drawn from the coil. It can be carried out.
[0038]
【The invention's effect】
As described above, according to the motor part of the present invention, the linear portion is formed by the conductor having the rectangular flat plate cross section, and the bent portion is formed by the conductor having the trapezoidal cross section. It is possible to obtain heat dissipation and it is most suitable for application to a polyphase motor.
[0039]
According to the method of manufacturing a motor component of the present invention, the linear portion is formed of a conductive wire having a rectangular flat plate cross-section by intermittently performing uneven rolling in the width direction on the conductive wire having a rectangular flat cross-section. And a motor part in which the bent portion is formed of a conducting wire having a trapezoidal cross section can be easily obtained. In particular, a plurality of coils can be obtained with a series of conducting wires, and the manufacturability is excellent.
[Brief description of the drawings]
1A is a perspective view of a single coil used for a motor component of the present invention, FIG. 1B is a cross-sectional view of an X part in FIG. 1A, and FIG. 1C is a cross-sectional view of a Y part in FIG. .
FIG. 2 is an explanatory view of a step of manufacturing a first coil in the method of the present invention.
FIG. 3 is a schematic configuration diagram of a general motor.
FIG. 4 is a partial perspective view showing a state where the coil of FIG. 1 is mounted on a stator.
FIG. 5 is a plan view showing a state where the coil of FIG. 1 is mounted on a rotor.
FIG. 6 is a partial plan view of a stator using a conductor having a variable width and thickness.
FIG. 7 is an explanatory view showing a plurality of coils used for the motor component of the present invention.
FIG. 8 is an explanatory diagram of a step of manufacturing the coil of FIG. 7;
FIG. 9 is a configuration diagram showing a coil of a polyphase motor to which the method of the present invention is applied.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Conductor 2 Insulation coating 10 Coil 11 Straight part 12 Bent part 20 Cylindrical roller 21 (First) conical roller 22 Second conical roller 30 Rotor 40 Stator 41 Ring part 42 Projection part 50 Hall element 51 Inverter 60 Rotor 61 Ring part 62 Projection Part 70 Stator 80 Bending part

Claims (2)

A motor component having a core and a plurality of coils formed continuously by winding a conductive wire,
The core includes a ring portion, and a protrusion that extends in a radial direction of the ring portion and around which the conductive wire is wound,
The coil has a straight portion and a bent portion,
The conductive wire cross-sectional shape of the straight portion is a rectangular plate shape, and the conductive wire cross-sectional shape of the bent portion has a trapezoidal shape in which the thickness on the outer peripheral side of the bend is smaller than the thickness on the inner peripheral side,
Among the plurality of coils, the coils of the same phase are connected to each other via a bent portion obtained by bending the conductive wire,
A motor component, wherein the cross-sectional shape of the bent portion is a trapezoidal shape in which the thickness on the outer circumferential side of the bending is smaller than the thickness on the inner circumferential side. The cross section formed by rolling forms a straight portion by conveying a rectangular plate-shaped conductor linearly, and intermittently rolling one side edge side of the conductor wire larger than the other side edge to form a cross section. Forming a trapezoidal bent portion, forming a coil consisting of a straight portion and a bent portion,
After forming the coil, a step of rolling one side edge side of the conductive wire intermittently larger than the other side edge side intermittently, and forming a bent portion having a trapezoidal cross section continuously at the coil end portion,
After the formation of the bent portion, one side edge side of the conductive wire is intermittently rolled larger than the other side edge side to form a trapezoidal bent portion, and another portion including a straight portion and a bent portion is formed. Forming a coil continuously;
Fitting a protruding portion inside each of the coils.

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