JP2004312940A - Winding coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that a temperature rise by heating becomes great caused by the increase of wiring resistance at a narrower part due to a smaller cross-sectional area at the narrower part compared with cross-sectional areas of the other parts, since the narrower part with relatively narrower width is formed at prescribed intervals in the longitudinal direction of a straight-angle wire, the straight-angle wire is bent at the narrower part, and a winding coil with a small curvature at the bending part is formed in a conventional winding coil. <P>SOLUTION: A coil base material is formed by fitting a plurality of tubular conductors having a similar cross-sectional shape into a nesting form. The coil base material is spirally cut open. Each tubular conductor is formed into a straight-angle wire shape. Next, the cutting terminal end of one tubular conductor and the cutting initial end of the other tubular conductor, which are formed into the straight-angle wire shape, are successively connected electrically, and it is formed into the shape of one conducting wire. As a result, the winding coil can be provided which does not increase the winding resistance and which prevents the temperature rise by the heating. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a winding coil suitable for use in electric equipment such as a motor and a generator.
[0002]
[Prior art]
In general, it is advantageous to reduce the winding resistance of a winding coil used for an electric device such as a motor or a generator in order to reduce the loss and the size of the electric device. Further, when the winding resistance is large, the temperature rise due to heat generation becomes large, so that there is a problem that an insulating material having high heat resistance must be used.
[0003]
In view of this, there have been increasing the number of winding coils using rectangular wires, which can increase the conductor space factor as compared with conventional round conductors having a circular cross-sectional shape, and consequently reduce the winding resistance. Reference 1).
[0004]
[Patent Document 1]
Japanese Patent Application Laid-Open No. 2002-222724
[Problems to be solved by the invention]
However, in such a conventional winding coil, a narrow portion having a relatively small width is formed at predetermined intervals with respect to the longitudinal direction of the rectangular wire, and the rectangular wire is bent at the narrow portion. Forming a winding coil having a small curvature in the curved portion, the cross-sectional area of the narrow portion becomes smaller than the cross-sectional areas of other portions, and a new problem that the winding resistance increases in the narrow portion. Has occurred.
[0006]
[Means for Solving the Problems]
The present invention has been made in view of such a drawback of the conventional winding coil, and has as its object to provide a winding coil using a rectangular wire having a small winding resistance.
[0007]
In order to achieve the above object, a wound coil according to the present invention is configured such that a coil base material formed by nesting a plurality of tubular conductors having similar shapes in cross section is cut into a spiral shape, and each of the tubular coils is cut. The tubular conductor is formed in a rectangular wire shape, and then the cut end of one tubular conductor formed in the shape of a rectangular wire and the cut start end of the other tubular conductor are sequentially electrically connected to each other. Is formed in the shape of a conductive wire.
[0008]
The winding coil according to the present invention is characterized in that the tubular conductor has a cylindrical shape or a rectangular tubular shape.
[0009]
Furthermore, the winding coil according to the present invention is characterized in that the axial lengths of the cylindrical conductors are the same.
[0010]
Still further, the winding coil according to the present invention is characterized in that the axial length of each tubular conductor decreases as it goes to the outer peripheral side.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a first embodiment of a wound coil according to the present invention will be described in detail with reference to FIGS.
[0012]
FIG. 1 is a perspective view showing a plurality of rectangular tubular conductors 3-1 to 3-4 forming a coil base material 2 as a material of a winding coil 1 as one example of a first embodiment of the present invention. It is. Each of the rectangular tubular conductors 3-1 to 3-4 has a similar shape, and an insulating film is formed on a peripheral surface thereof by appropriately selecting a resin such as enamel, polyurethane, or polyester in accordance with a use environment.
The rectangular tubular conductor 3-1 fits into the inner surface of the rectangular tubular conductor 3-2 without a gap, and the rectangular tubular conductor 3-2 fits into the inner surface of the rectangular tubular conductor 3-3 without a gap. The rectangular tubular conductor 3-3 has a size that can be fitted into the inner surface of the rectangular tubular conductor 3-4 without a gap.
[0013]
FIG. 2 is a view showing a coil base material 2 formed by fitting each of the rectangular tubular conductors 3-1 to 3-4 shown in FIG. The portion between 3 and 4 is kept electrically insulated by an insulating film applied to the peripheral surface.
[0014]
FIG. 3 is a perspective view showing a state in which the coil base material 2 composed of the rectangular tubular conductors 3-1 to 3-4 is being spirally cut, and a flat rectangular shape forming the later-described winding coil 1 is shown. 4 illustrates a process of forming the lines 4-1 to 4-4 and a state of forming the flat lines 4-1 to 4-4.
Here, the rectangular wire 4-1 represents the rectangular tubular conductor 3-1; the rectangular wire 4-2 represents the rectangular tubular conductor 3-2; the rectangular wire 4-3 represents the rectangular tubular conductor 3-3; Reference numeral 4-4 is formed by cutting the rectangular cylindrical conductor 3-4. In addition, for cutting the rectangular tubular conductors 3-1 to 3-4, various types such as a wire cutter, a laser cutter, and a carbide rotary blade are selectively used according to the material of the rectangular tubular conductors 3-1 to 3-4.
[0015]
FIG. 4 shows a state in which the spiral cutting of the coil base material 2 composed of the rectangular tubular conductors 3-1 to 3-4 in FIG. 3 is completed, and the flat rectangular cut out from the rectangular tubular conductors 3-1 to 3-4. FIG. 4 shows a perspective view of the entire line 4-1 to 4-4.
[0016]
In FIG. 4, reference numeral 4A denotes a circuit start end as a cutting start end from which a thin portion at the front end is cut, and 4B denotes a circuit end portion as a cut end portion from which a thin portion at the rear end is cut.
The circuit start end 4A is formed by bending the start ends 4A-1 to 4A-4 of the rectangular wires 4-1 to 4-4, and the circuit terminal 4B is the terminal 4B of the rectangular wires 4-1 to 4-4. -1 to 4B-4 are formed by bending.
[0017]
After the rectangular wires 4-1 to 4-4 are formed as shown in FIG. 4, at least the cut surfaces of the rectangular tubular conductors 3-1 to 3-4 are provided on the cut surfaces of the rectangular tubular conductors 3-1 to 3-4. Apply the same insulating coating as that applied to the surface. Thereby, the insulated state is maintained even if the flat wires contact each other.
[0018]
Reference numeral 5 denotes a connection line for electrically connecting the end 4B-1 of the flat wire 4-1 and the start 4A-2 of the flat wire 4-2.
Reference numeral 6 denotes a connection line that electrically connects the end 4B-2 of the flat wire 4-2 and the start 4A-3 of the flat wire 4-3.
Reference numeral 7 denotes a connection line for electrically connecting the end 4B-3 of the flat wire 4-3 and the start 4A-4 of the flat wire 4-4.
[0019]
As a result, the wire from the start 4A-1 of the flat wire 4-1 to the end 4B-4 of the flat wire 4-4 is electrically connected as one conductive wire, and the coil 1 is formed.
[0020]
FIG. 5 is a partial cross-sectional perspective view showing an example in which two winding coils 1A and 1B are mounted on a stator core 8.
[0021]
In FIG. 5, reference numeral 9 denotes a holding plate for preventing the wound coils 1A and 1B inserted into the teeth portion 10 from falling off, and the holding plate 9 is locked between the adjacent teeth portions 10.
[0022]
Reference numeral 11 denotes a connection line for electrically connecting the adjacent winding coils 1A and 1B, and the connection line 11 is a terminal end of a flat wire 4-4 which is a winding end of the adjacent winding coil 1A. 4B-4 and the start end 4A-1 of the flat wire 4-1 which is the winding start end of the winding coil 1B are connected.
[0023]
FIG. 6 is a partial cross-sectional perspective view showing another example in which two winding coils 1A and 1B are mounted on the stator core 8.
[0024]
In FIG. 6, reference numeral 12 denotes a buffer band formed between the adjacent winding coils 1A and 1B. The other configuration is the same as that of the example shown in FIG. 5, and the description is omitted.
[0025]
In this example, the winding coils 1A and 1B are formed as shown in FIG.
That is, after the winding coil 1A is formed, the rectangular wires 4-1 to 4-4 are directly stretched from the circuit end 4B of the winding coil 1A to the circuit start 4A of the winding coil 1B, and the winding coil 1B is continuously formed. Are formed continuously.
The end 4B-4 of the flat wire 4-4 in the continuously formed winding coil 1A and the starting end 4A-4 of the flat wire 4-4 in the winding coil 1B are used as the buffer band 12, and both coils 1A, 1B is integrally formed without any electrical loss.
Thereafter, both coils 1A and 1B are formed so as to be inserted into teeth portion 10 of stator core 8 as shown in FIG.
[0026]
Here, the end portions 4B-1 to 4B-3 of the rectangular wires 4-1 to 4-3 in the continuously formed winding coil 1A and the starting ends 4A- of the rectangular wires 4-1 to 4-3 in the winding coil 1B. A portion corresponding to the length corresponding to the buffer band 12 has been cut off between 1 and 4A-3.
[0027]
In the other example of the present embodiment shown in FIG. 6, the two winding coils 1A and 1B are formed integrally, but three or more winding coils are formed integrally. Is also good.
[0028]
Thus, according to another example of the present embodiment shown in FIG. 6, the connection line 11 as in the example shown in FIG. 5 is not required, and the connection failure can be prevented.
[0029]
Further, by forming the plurality of winding coils 1A and 1B in accordance with the facing angle of the teeth portion 10 to be inserted and the curvature of the stator core 8, the insertion into the teeth portion 10 is facilitated and the buffer band is formed. Since the body 12 is formed so as to be extendable and contractible, it can be easily and reliably mounted on the stator core 8 even if there is a slight curvature mismatch or the like.
[0030]
Although the present embodiment is configured as described above, the shape of the winding coil 1 and the winding coils 1A and 1B is not limited to a rectangular shape, and as shown in FIG. Various polygonal shapes, elliptical shapes, and the like can be used depending on the shape of the teeth portion or the core.
[0031]
Further, in the present embodiment, the configuration has been described in which the winding coil is formed by using the cylindrical conductor having the peripheral surface coated with the insulating film. However, the present invention is not limited to this. It is also possible to adopt a configuration in which a coil base material is cut spirally to form a winding coil without applying an insulating film, and then an insulating film is applied to the entire winding coil using various known film forming means. .
[0032]
Next, a second embodiment of the wound coil according to the present invention will be described in detail with reference to FIGS.
[0033]
The difference between the present embodiment and the first embodiment is that, in order to reduce the air gap between the adjacent winding coils and increase the conductor space factor, the axial length of the cylindrical conductor used as the material of the winding coil is different. The length is shortened toward the outer peripheral side.
[0034]
That is, as shown in FIG. 10, a coil base material 22 serving as a material of the winding coil 21 is provided on the outer periphery of the coil base material 2 in the first embodiment by a plurality of corners having a shorter axial length than the coil base material 2. It is formed by inserting the tubular conductors 23-1 and 24-1.
Here, the coil base material 2 fits into the inner surface of the rectangular tubular conductor 23-1 without a gap, and the rectangular tubular conductor 23-1 has a size that can fit into the inner surface of the rectangular tubular conductor 24-1 without a gap. Has become.
[0035]
FIG. 11 is a diagram showing a coil preform 22 formed by fitting the coil preform 2 shown in FIG. 10 and the rectangular tubular conductors 23-1 and 24-1 in a nested manner without gaps. In addition, the space between the rectangular tubular conductors 23-1 and 24-1 is maintained in an electrically insulated state by an insulating film provided on the peripheral surface.
[0036]
FIG. 12 is a perspective view showing a state where the coil base material 22 including the coil base material 2 and each of the rectangular tubular conductors 23-1 and 24-1 is being spirally cut out. This shows the formation process of the rectangular wires 4-1 to 4-4, 25-1, 26-1 forming the coil 21 and the formation state of the rectangular wires 4-1 to 4-4, 25-1, 26-1. .
Here, the flat wire 25-1 is formed by cutting the rectangular tubular conductor 23-1, and the flat wire 26-1 is formed by cutting the rectangular tubular conductor 24-1.
[0037]
FIG. 13 shows that the coil base material 22 and the square base conductors 23-1 and 24-1 shown in FIG. It is a perspective view of the whole rectangular wires 4-1 to 4-4, 25-1, and 26-1 cut out from 23-1 and 24-1.
[0038]
In FIG. 13, reference numeral 25A denotes a circuit start end as a cutting start end obtained by cutting a thin portion at the front end, and 25B denotes a circuit end portion serving as an incision end portion obtained by cutting a thin portion at the rear end.
The circuit start part 25A is formed by bending the start part 25A-1 of the rectangular wire 25-1, and the circuit terminal part 25B is formed by bending the terminal part 25B-1 of the rectangular wire 25-1.
Similarly, 26A is a circuit starting end as a cutting start end where a thin portion at the front end is cut off, and 26B is a circuit terminal end as a cutting end portion as a cutting end where a thin portion at the rear end is cut off.
The circuit start end 26A is formed by bending the start end 26A-1 of the rectangular wire 26-1 and the circuit end 26B is formed by bending the end 26B-1 of the rectangular wire 26-1.
[0039]
Reference numeral 27 denotes a connection line for electrically connecting the end 4B-4 of the flat wire 4-4 and the start end 25A-1 of the flat wire 25-1.
Reference numeral 28 denotes a connection line that electrically connects the end portion 25B-1 of the flat wire 25-1 and the start end 26A-1 of the flat wire 26-1.
[0040]
As a result, the wire from the start 4A-1 of the flat wire 4-1 to the end 26B-1 of the flat wire 26-1 is electrically connected as one conductive wire, and the coil 21 is formed.
[0041]
FIG. 14 is a partial cross-sectional perspective view showing an example in which two winding coils 21A and 21B are mounted on the stator core 8.
[0042]
In FIG. 14, reference numeral 9 denotes a holding plate for preventing the winding coils 21A and 21B inserted into the teeth portion 10 from falling off. The holding plate 9 is locked between the adjacent teeth portions 10.
[0043]
Reference numeral 29 denotes a connection line for electrically connecting the adjacent winding coils 21A and 21B, and the connection line 29 is a terminal end of a flat wire 26-1 serving as a winding end of the adjacent winding coil 21A. 26B-1 and the start end 4A-1 of the rectangular wire 4-1 which is the winding start end of the coil 21B.
[0044]
By the way, in this embodiment, as shown in FIG. 15, when the winding coil 21A is inserted into the teeth portion 10 and then the winding coil 21B is integrally inserted into the teeth portion 10, it interferes with the winding coil 21A. , The later winding coil 21B cannot be inserted.
[0045]
Therefore, in order to insert the winding coils 21A and 21B in this embodiment, as shown in FIG. 16, first, the rectangular wire 26-1 is inserted into the tooth portion 10, and then the rectangular wire 25-1 is inserted into the tooth portion 10. Finally, the rectangular wires 4-1 to 4-4 may be inserted.
[0046]
Although the present embodiment is configured as described above, the shape of the winding coil 21 and the winding coils 21A and 21B is not limited to a rectangular shape, and as shown in FIG. Various polygonal shapes, elliptical shapes, and the like can be used depending on the shape of the teeth portion or the core.
[0047]
As described above, each embodiment of the present invention has been described in detail with reference to the drawings. However, the present invention is not limited to each embodiment, and various modifications may be made thereto within the scope of the claims. It is possible to apply and implement.
[0048]
【The invention's effect】
Since the winding coil according to the present invention is configured as described above, not only does the winding resistance not increase at the bent portion as in the conventional winding coil, but also the conductor space factor can be increased. it can.
[0049]
In addition, a rectangular wire can be freely formed by selecting a tubular conductor block for a winding coil corresponding to a tooth portion or a core having various shapes.
[0050]
Further, in the present invention, the required magnetic flux density can be easily obtained by changing the number of cylindrical conductors or adjusting the cut angle of the coil base material.
[0051]
Furthermore, since a plurality of tubular conductors are evenly spirally cut to form a rectangular wire, and the winding coil is formed using the uniform rectangular wire, the width is narrower than a conventional rectangular wire. Another feature is that it is not necessary to consider an increase in winding resistance due to overlap.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a plurality of rectangular tubular conductors forming a coil base material serving as a material of a winding coil according to an example of a first embodiment of the present invention; FIG. 3 is a view showing a coil base material in one example. FIG. 3 is a perspective view showing a state in which the coil base material is being spirally cut in one example in the first embodiment. FIG. FIG. 5 is a perspective view showing the entire rectangular wire cut from the rectangular tubular conductor after the spiral cutting of the coil base material in one example of the embodiment is completed. FIG. 5 is a winding coil in one example of the first embodiment. FIG. 6 is a partial cross-sectional perspective view showing an example in which a winding coil according to another example of the first embodiment is mounted on a stator core. FIG. 8 is a diagram showing the shape of a continuous winding coil in another example of the first embodiment. FIG. 9 is a diagram showing a shape of a wound coil formed to be inserted into a tooth portion in the example of FIG. 9; FIG. 9 is a diagram showing a modification of the shape of a wound coil in the first embodiment; FIG. FIG. 11 is a perspective view showing a plurality of rectangular tubular conductors forming a coil base material serving as a material of a winding coil according to the second embodiment. FIG. 11 is a view showing a coil base material according to the second embodiment. FIG. 13 is a perspective view showing a state in which the coil base material in the embodiment is being spirally cut in a spiral manner. FIG. 13 is a view illustrating a state in which the spiral cutting of the coil base material in the second embodiment is completed and is cut out from the rectangular tubular conductor. FIG. 14 is a partial cross-sectional perspective view showing an example in which a winding coil according to the second embodiment is mounted on a stator core; FIG. 15 is a view taken in the direction of arrow A in FIG. 14; Insert the winding coil in the second embodiment into the teeth part Figure [EXPLANATION OF SYMBOLS] showing a modification of the shape of the winding coil in FIG. 17 is a second embodiment for explaining a procedure for
1, 13, 21, 30 Wound coil 2, 22 Coil base materials 3-1 to 3-4, 23-1, 24-1 Square tubular conductors 4-1 to 4-4, 25-1, 26-1 Rectangular wires 4A, 25A, 26A Circuit start portions 4A-1 to 4A-4, 25-A1, 26A-1 Start ends 4B, 25B, 26B Circuit end portions 4B-1 to 4B-4, 25B-1, 26B-1 Ends 5, 6, 7, 11, 27, 28, 29 Connecting wire 8 Stator iron core 9 Holding plate 10 Teeth portion 12 Buffer band

Claims (4)

A coil base material formed by nesting a plurality of tubular conductors having similar shapes in cross section is cut into a spiral shape, and each tubular conductor is formed into a rectangular wire, and then formed into a rectangular wire. A winding coil, wherein a cut end of one tubular conductor and a cut start end of another tubular conductor are sequentially electrically connected to form a single conductive wire. The winding coil according to claim 1, wherein the cylindrical conductor has a cylindrical shape or a rectangular cylindrical shape. The coil according to claim 1, wherein each of the cylindrical conductors has the same axial length. 3. The winding coil according to claim 1, wherein the length of each of the cylindrical conductors in the axial direction is reduced as it goes to the outer peripheral side.

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