JP2005110456A - Motor coil, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a motor coil, along with its manufacturing method, which realizes, for example, a slotless motor of high efficiency. <P>SOLUTION: A motor coil component 1000 comprises a plurality of swirl parts 110α-110δ where a wire material is at least wound in edgewise, and crossover parts 120a-120c that connect the swirl parts together. The crossover part is provided to connect the outermost peripheries of the swirl parts together. Each of the swirl parts 110α-110δ has at least a hollow part 111 at its center and has a pair of straight parts 112a-112h facing each other across the hollow part 111. The hollow part 111 has a gap which is substantially integral multiple of the width of the straight part 112a. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a motor coil used for a slotless motor, a linear motor, and the like, a manufacturing method thereof, and the like.

  Conventionally, a slotless motor having a configuration in which a slot is omitted is widely used along with a motor having a configuration in which a coil is wound around a winding groove (slot) formed in a rotor or a stator.

  Here, FIGS. 24 (a) and 24 (b) show the configuration of the main part of such a conventional slotless motor. 24A is a schematic side view, and FIG. 24B is an end view. As shown in both figures, the slotless motor 2400 includes a rotor 2420 having a permanent magnet 2410 provided around it, a substantially cylindrical three-layer four-pole motor coil 2430 and a motor coil 2430 that house the rotor 2420. A substantially cylindrical stator yoke 2440 to be housed and a housing portion 2450 to house these parts are provided. Although not shown, the end portion of the rotor 2420 is exposed to the outside from the housing portion 2450 and transmits the rotational force to the outside.

  In the illustrated rotor 2420, most of the shaft housed in the motor coil 2430 has a shape that is narrower than the other portions, and a permanent magnet 2410 is provided in the narrowed portion. The permanent magnet 2410 faces the inner wall of the stator yoke 2440 with the motor coil 2430 interposed therebetween.

  Next, a manufacturing method of the motor coil 2430 will be described with reference to FIGS. 25 to 33 (for details, see, for example, Patent Document 1).

  First, as shown in FIG. 25, the first insulated conductor 38, the second insulated conductor 40, and the third insulated conductor 42 are wound around the mandrel 58.

  Next, as shown in FIGS. 25 and 26, the first insulated conductor 38 has a first end 44 and a second end 46, and the second insulated wire 40 has a first end 48 and a second end 50. The third insulated conductor 42 has a first end 52 and a second end 54. The mandrel 58 has a symmetrical shape about the axis 60.

  Next, as shown in FIG. 26, the first, second, and third insulated conductors 38, 40, 42 are simultaneously in the first direction indicated by the downward arrow in FIG. The first coil unit 64, the second coil unit 66, and the third coil unit 68 are formed by winding. This winding process can be performed by rotating the mandrel 58 or by mechanically guiding each of the insulated conductors 38, 40, 42 around the mandrel 58. Accordingly, in FIG. 26, the first insulated conductor 38 is wound around the mandrel 58 in the clockwise direction to form the first coil unit 64. The second insulated conductor 40 is also wound around the mandrel 58 in the clockwise direction to form a second coil unit 66. The third insulated conductor 42 is also wound in the clockwise direction simultaneously with the winding of the first and second coil units 64 and 66 to form the third coil unit 68.

  Each coil unit 64, 66, 68 is formed by winding the respective insulated conductors 38, 40, 42 around the mandrel 58 8 to 12 times. The first, second, and third coil units 64, 66, 68 form a configuration called a first coil group 62 of coils.

  Once the first group of coil units 62 is wound, the insulated conductors 38, 40, 42 are placed over a mandrel 58 over a distance of approximately twice the width of one of the coil units 64, 66, 68. The axis 60 is moved in the axial direction. These axial movements of the three insulated conductors 38, 40, 42 are shown in FIG. 26 as 70, 72, 74, respectively. The first movement 70 of the first insulated conductor 38 positions the insulated conductor 38 immediately next to the last winding of the third coil unit 68 as shown in FIG. The first movement 72 of the second insulated conductor 40 is further spaced apart by approximately one coil unit width along the mandrel 58 from where the first movement 70 of the first conductor 38 ends. The first movement 74 of the conductor 42 is further spaced apart by a width of one coil unit along the mandrel from where the first movement 72 of the second conductor 40 ends. Thus, the insulated conductors 38, 40, 42 are positioned so as to wind the second group 76 of coil units.

  The second group 76 composed of the coil units is wound in a second direction opposite to the winding direction of the first group 62 composed of the coil units. In the configuration shown in FIG. 26, the second group 76 of coil units is wound in the counterclockwise direction as indicated by the upward arrow. The first, second, and third insulated conductors 38, 40, 42 were used to wrap the first group 62 of coil units to wrap the second group 76 of coil units. Wind the same number of times counterclockwise at the same time. As a result, the first insulated conductor 38 forms the fourth coil unit 78, the second insulated conductor 40 forms the fifth coil unit 80, and the third insulated conductor 42 forms the sixth coil unit 82. Once the coil units 78, 80, 82 are wound, in order to position the conductors 38, 40, 42 with respect to the third group 90 of coil units, the insulated conductors 38, 40, 42 have a width equivalent to two coil units. A second move is made over an approximately equal distance.

  Thus, the first insulated lead 38 takes a second axial adjustment 84, the second insulated lead 40 takes a second axial adjustment 86, and the third insulated lead 48 takes a second axial adjustment 88. In order to wind the third group 90 made of the coil unit, the insulated conductors 38, 40, 42 are arranged in the direction opposite to the winding direction of the second group 76 made of the coil unit, and the first group made of the coil unit. Wind in the same direction as the winding direction of 62. In the illustrated configuration, the third group 90 of coil units is wound in a clockwise direction as indicated by a downward mark in FIG. The first, second, and third insulated conductors 38, 40, 42 are wound at the same time as many times as the first and second coil groups 62, 76 are wound. As a result, the first insulated conductor 38 forms the seventh coil unit 92, the second insulated conductor 40 forms the eighth coil unit 94, and the third insulated conductor 42 forms the ninth coil unit 96.

  At this point, the insulated conductors 38, 40, 42 are simultaneously moved in the axial direction by a distance substantially equal to the width of two coil units. The movement of the first insulated conductor 38 in the third axial direction is indicated by reference numeral 98 in FIG. The third axial movement of the second insulated conductor 40 is indicated by reference numeral 100, and the third axial movement of the insulated conductor 42 is indicated by reference numeral 102 in FIG. After the insulated conductors 38, 40, 42 are once positioned in this manner, the fourth group 104 composed of coil units is wound in the same direction as the winding direction of the second coil group 76. In the configuration shown in FIG. 26, this is a counterclockwise winding, in which the first insulated conductor 38 forms the tenth coil unit 106, the second insulated conductor 40 forms the eleventh coil unit 108, and the third The insulated conductor 42 forms the twelfth coil unit 10. After winding the fourth group 104 of coils, the second ends 46, 50, 54 of the respective conductors 38, 40, 42 will be described in detail below after fabrication of the field coil 24. , Extending from the preformed wire assembly 36 for later connection.

  Next, as shown in FIGS. 27, 28 and 29, there is a structure in which the winding assembly 36 can be taken out from the hexagonal mandrel 58 without changing the shape of the coil in the winding assembly 36 or the relationship between them. And affixed to the formed wire assembly 36. Preferably, the securing structure takes the form of at least two strips of adhesive tape 114 and 118 that are applied longitudinally with respect to the axis of the mandrel 58 along both outer surfaces of the winding assembly 36. As shown in FIG. 27, a first strip 114 of adhesive tape is applied longitudinally along one outer surface of the assembly 36. The second strip 118 is attached to the outer surface of the winding assembly 36 opposite to the outer surface to which the first strip 114 is attached. At this point, the winding assembly 36 is removed from the mandrel 58.

  After removal of the winding assembly 36 from the mandrel 58, the insert 122 is preferably inserted into the winding assembly 36 as seen in FIGS. The insert 122 is most preferably a strip formed of “B” stageable glass fiber with an epoxy coating, preferably two of the vertices of the inner periphery of the hexagonal shaped wire assembly 36. Slightly less than the maximum distance between two vertices.

  Next, as shown in FIGS. 30 and 31, the secured winding assembly 36 with the insert 122 therein is flattened to form a substantially flat bilayer web 138. This web has an axial first end 124 formed by the first coil unit 64 and an axial second end 128 formed by the twelfth coil unit 110. As best shown in FIG. 31, the flat bilayer web 138 has a first layer 132 and a second layer 134 opposite the first layer 132. The core 136 formed by the insert 122 is positioned between the first and second layers 132, 134.

  As can be seen in FIG. 30, the flattening process includes a front single-layer web portion 126 formed on the second axial end 128 side of the web 138 and a rear single-layer web portion 130 first in the axial direction of the web 138. The first layer 132 of the web 138 is shifted with respect to the second layer 134 with respect to the axial direction to the extent that it is formed on the end 124 side. Preferably, the offset is such that, as can be seen in FIG. 30, the single-layer web portion 126 in front of the second axial end 128 of the web consists exclusively of the coil units 106, 108, 110 constituting the fourth coil group 104. It is performed to the extent that it is formed from the surrounding segments or legs 106a, 108a, 110a (hereinafter referred to as the front legs 106a, 108a, 110a) in the axial front side, so that the rear side of the first axial end 124 of the web The single-layer web portion 130 of the first embodiment is mainly composed of peripheral segments or legs 64b, 66b, 68b (hereinafter referred to as rear legs 64b, hereinafter) in the axial direction of the coil units 64, 66, 68 constituting the first coil group 62. 66b and 68b).

  As a result, the front leg portions 64a, 66a, 68a of the individual coil units 64, 66, 68 in the first coil group 62 are the fourth coils wound in the opposite direction by the front leg portions 64a of the first coil unit 64. It overlaps with the rear leg portion 78b of the unit 78, and the front leg portion 66a of the second coil unit 66 overlaps with the rear leg portion 80b of the fifth coil unit 80 wound in the opposite direction. The portion 68a is shifted to the extent that it overlaps the rear leg portion 82b of the sixth coil unit 82 wound in the opposite direction. Similarly, the front leg portions 78a, 80a, 82a of the fourth, fifth, and sixth coil units 78, 80, 82 of the second coil group 76 have seventh, eighth, and eighth windings wound in opposite directions. The nine-coil units 92, 94, 96 are shifted so as to overlap the rear legs 92b, 94b, 96b, respectively. Similarly, the front legs 92a, 94a, 96a of the seventh, eighth, and ninth coil units 92, 94, 96 are the tenth, eleventh, and twelfth coil units 106, 108 wound in opposite directions. , 110 are shifted so as to overlap the rear leg portions 106b, 108b, 110b. Similarly, as can be seen in the assembly process shown in FIG. 32, the front legs 106a, 108a, 110a of the tenth, eleventh, and twelfth coil units 106, 108, 110 are the first and second ends of the web 138. When 124 and 128 are joined together, they are shifted so as to finally overlap the rear leg portions 64b, 66b and 68b of the first, second and third coil units 64, 66 and 68 wound in opposite directions. ing.

  As a result, when the ends 124 and 128 of the web 138 are joined to each other, each of the front legs 64a, 78a, 92a, and 106a wound with the first insulated conductor 38 is wound with the first insulated conductor 38. It overlaps with the rear leg portions 78b, 92b, 106b, 64b of the next coil unit wound in the opposite direction. Each of the front legs 66a, 80a, 94a, 108a around which the second insulated conductor 40 is wound is a rear leg 80b of the coil unit wound in the next continuous opposite direction around which the second insulated conductor 40 is wound. , 94b, 108b, 66b. Similarly, each of the front legs 68a, 82a, 96a, 110a around which the third insulated conductor 42 is wound is arranged on the rear side of the coil unit wound in the next continuous opposite direction around which the third insulated conductor 42 is wound. It overlaps with the leg portions 82b, 96b, 110b, 68b. As a result, the currents of the legs of the overlapping coil units flow in the same direction, and as a result, mutually reinforcing electromagnetic fields that do not affect the respective actions are obtained. Note that this occurs regardless of the particular wire connection configuration applied to the winding.

  Further, as shown in FIG. 32, the front monolayer web portion 126 at the second axial end 128 of the flat web 138 overlaps the rear monolayer web portion 130 at the first axial end 124. The flat web 138 is rolled to face the ends. As a result, a motor coil 2430 having a cylindrical shape is produced. However, as shown in FIG. 29, when the lead wire is folded with the insert 122 as a corner, an excessive thickness is generated, and the thickness of both end portions is actually thicker than the center portion.

  Finally, as shown in FIG. 33, the motor coil 2430 is inserted into a cylindrical space formed by the inner wall of the stator core 2410.

In the slotless motor having the above-described configuration, the motor coil 2430 is uniformly arranged along the rotation circumference of the rotor 2420, and the rotor 2420 receives a uniform magnetic attraction force at any position. Cogging does not occur, torque unevenness and rotation unevenness characteristics are not adversely affected, and the characteristics are higher than a motor having a slot.
Japanese Patent No. 2799395

  In order to accurately rotate the slotless motor, it is important to keep the magnitude of the rotating magnetic field in the motor coil 2430 serving as a stator constant. Even if the working accuracy of the rotor 2430 serving as the rotor is good, torque pulsation and rotation unevenness may occur if a constant rotating magnetic field cannot be obtained. Therefore, how to accurately finish the stator core and motor coil for generating the rotating magnetic field is important.

  In the slotless motor, the accuracy of the rotating magnetic field is determined by the shape of the conductor of the motor coil and the accuracy of the arrangement of each conductor in the motor coil. In the slotless motor 2400, as shown in FIG. 24B, since the permanent magnets 2410 are provided radially from the center of the rotor 2420, the magnetic field generated by the motor coil 2430 corresponds to this, Desirably, they are generated radially separated from the center of the rotor 2420.

  An example of an ideal magnetic field distribution is shown in FIG. For the four permanent magnets 2410 provided radially with respect to the rotor 2420, the magnetic field formed by the motor coil 2420 is equally divided into four regions A to D, and adjacent regions have poles opposite to each other. ing. In addition, the boundaries between the regions are also formed radially from the center of the rotor 2420 and form the normal line of the outer periphery of the motor coil 2430.

  However, when the motor coil 2430 is manufactured by the processes shown in FIGS. 25 to 33, this is a method of crushing the coil wound in a spiral shape into a flat shape. Therefore, as shown in FIG. The first insulated conductor 38, the second insulated conductor 40, and the third insulated conductor 42 seem to be densely packed, but when creating a cylindrical shape in a roll shape, the arrangement of the conductors is a motor coil. As shown in FIG. 35, the arrangement of each leg portion collapses in the circumferential direction of 2430, and the boundary of the magnetic field formed by each insulated conductor is formed obliquely along the cross section of the coil winding.

  At this time, as shown in FIG. 36, the boundaries of the different magnetic fields formed by the motor coil 2420 are also formed obliquely along the cross section of the coil winding, and become the original poles (the current flows in order). A region 3600 indicated by a hatched portion in the figure, which is made of a copper wire (current flows in the opposite direction), which is the opposite pole, enters the region that should flow in the direction. That is, the region 3600 generates a magnetic field in the direction opposite to the original direction. The numbers in FIG. 35 and FIG. 36 correspond to the numbers of the legs shown in FIG. 30, and mean the areas occupied by the legs in the coil.

  The magnetic flux in the region 3600 changes depending on the phase of the current flowing in each coil, and is different from the magnetic flux assumed in the original region. This means that an accurate circular rotating magnetic field cannot be generated. When an antiphase current flows through the motor coil shown in FIG. 36, the magnetic flux in the region 3600 becomes zero. If the ratio of the area 3600 occupying the entire motor coil is 10%, the magnetic flux is reduced by 10%, and when converted to torque, it is assumed to be reduced by about 20%. Further, in the case of a current of the same phase, the magnetic flux distribution can be uneven.

  Furthermore, the way the wire collapses is indeterminate, which may make the motor coil thickness, cross-sectional shape and area non-uniform.

  These conditions caused a drop in the efficiency of slotless motors.

  The present invention has been made in view of the above-described problems, and uses a motor coil that can be applied to a slotless motor with higher efficiency than conventional ones, in which the generated magnetic field does not cancel out due to overlap. An object of the present invention is to provide a slotless motor. Moreover, it aims at providing the manufacturing method for obtaining the motor coil of the said invention.

In order to achieve the above object, the first aspect of the present invention includes a plurality of spiral portions formed by winding a wire in a coil shape,
A connecting portion connecting the spiral portions,
Each of the spiral portions has a hollow portion at least in the center thereof and a pair of straight portions opposed to each other with the hollow portion interposed therebetween, and the hollow portion has a substantial width of the straight portion. This is a motor coil having an upper integer multiple gap.

  Further, the second aspect of the present invention is the motor coil according to the first aspect of the present invention, wherein the plurality of spiral portions have the same winding direction.

  Moreover, 3rd this invention is a motor coil of 1st this invention in which the said transition part is arrange | positioned on the same straight line.

Moreover, 4th this invention is arrange | positioned so that only one side of a pair of said linear part of each said adjacent spiral part may overlap with each other,
The pair of overlapping linear portions is the motor coil according to any one of the first to third aspects of the present invention, in which the winding direction is the same.

In the fifth aspect of the present invention, the spiral portion is formed by alpha winding.
The transition part is the motor coil according to any one of the first to fifth aspects of the present invention, which is provided so as to connect the outermost circumferences of the spiral part.

  The sixth aspect of the present invention is the motor coil according to any one of the first to fourth aspects of the present invention, wherein the spiral portion is formed by edgewise winding.

  The seventh aspect of the present invention is the motor coil according to any one of the first to fourth aspects of the present invention, wherein the spiral part and the transition part are constituted by a single continuous wire.

  The eighth invention is the motor coil according to any one of the first to fourth inventions, wherein the wire is a flat wire.

The ninth invention is a motor coil in which a plurality of the motor coils according to any one of the first to eighth inventions are stacked so that the principal surfaces of the spiral portions face each other.
The plurality of motor coils overlap with each other while shifting by one width of the linear portion,
When viewed from the main surface side of the spiral portion, the linear portion of the spiral portion of another motor coil is housed one by one in the hollow portion of the spiral portion of one motor coil.

  A tenth aspect of the present invention is a motor coil obtained by rounding the motor component of the ninth aspect of the present invention into a cylindrical shape so that the transition portion comes to an edge thereof.

The eleventh aspect of the present invention is a method of manufacturing a motor coil according to the first aspect of the present invention,
From a single wire, comprising the step of creating a plurality of the spiral portion at a predetermined length interval,
It is a manufacturing method of a motor coil which uses the part of the above-mentioned predetermined length of the above-mentioned wire rod as the above-mentioned crossing part.

A twelfth aspect of the present invention is a method for manufacturing a motor coil according to the fourth aspect of the present invention,
A step of creating a plurality of the spiral portions with a predetermined length interval from one wire,
The predetermined length portion of the wire is used as the transition portion, and the transition portion is bent so that only one of the pair of linear portions overlaps the pair of linear portions of the adjacent spiral portions. A step of arranging,
A step of creating a plurality of the spiral portions at a predetermined length interval from a single wire so that the pair of overlapping linear portions have the same winding direction;
The predetermined length portion of the wire is used as the transition portion, and the transition portion is bent so that only one of the pair of linear portions overlaps the pair of linear portions of the adjacent spiral portions. A step of arranging,
The pair of overlapping linear portions is a method of manufacturing a motor coil in which the winding direction is the same.

A thirteenth aspect of the present invention is the method for manufacturing a motor coil according to the first or fourth aspect of the present invention,
Creating the spiral portion from a single wire;
A method of manufacturing a motor coil, comprising: connecting a plurality of spiral portions with a wire having a predetermined length; and using the wire having the predetermined length as the transition portion.

The fourteenth aspect of the present invention is the motor coil according to any one of the first to fourth aspects of the present invention,
It is a linear motor provided with a plurality of cores arranged on a straight line which fits in the central portion of each of the plurality of spiral portions of the motor coil.

The fifteenth aspect of the present invention is the motor coil of the tenth aspect of the present invention,
The slotless motor includes a cylindrical stator yoke into which the motor coil is inserted.

  According to the present invention, it is possible to provide, for example, a motor coil capable of realizing a highly efficient slotless motor.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
FIGS. 1A and 1B are diagrams showing a configuration of a motor coil component 1000 for creating a motor coil according to Embodiment 1 of the present invention. 1A is a front view, and FIG. 1B is a plan view.

  As shown in FIGS. 1 (a) and 1 (b), the motor coil component 1000 of the present invention is configured by drawing a single continuous wire, and includes spiral portions 110α to 110δ and spiral portions 110α to 110δ. It is comprised from the transition parts 120a-120c which connect between each.

  Here, the wire is a rectangular wire having a rectangular cross section, and the spiral portions 110α to 110δ are constituted by alpha winding and edgewise winding. That is, the spiral portion 110α is composed of a pair of opposed spiral coils connected at the innermost peripheral portion. Therefore, the wire rod which has begun to be wound from one end and constitutes the spiral portion 110α, the other end reaches the outermost periphery of the spiral portion 110α and constitutes the transition portion 120a. The spiral portions 110β to 110δ and the transition portions 120b and 120c are also configured as described above. At this time, the spiral portions 110α to 110δ all have the same winding direction of the wire. Moreover, the transition parts 120a-120c are provided so that it may line up on the same straight line. In addition, as a wire, the surface shall be coat | covered and insulated.

  Next, details of the spiral portion will be described. The spiral part 110α is wound so as to form the hollow part 111. Furthermore, it has straight portions 112a and 112b made of a wire extending in a straight line, facing this hollow portion 111, and portions other than the straight portions 112a and 112b are rounded. As a result, the winding direction of the straight portion is opposite. Note that the spiral portions 110β to 110δ have the same configuration. Moreover, although the hollow part 111 has a substantially oval shape, the length on the short side, that is, the width is substantially twice the lateral width of the straight part.

  Moreover, the arrow in a figure shows the direction of the winding which goes to the end of winding from the winding start of a wire, and in each spiral part, a pair of linear part has a mutually different winding direction.

  In FIG. 1B, the thickness of the motor coil component 1000 is shown with the thickness of the spiral portions 110α to 110δ as one unit. The same applies to the following drawings and description.

  A method of manufacturing the motor coil 1 according to the first embodiment using such a motor coil component 1000 will be described with reference to FIGS.

  First, the motor coil component 200 shown in FIGS. 2A and 2B is created from the motor coil component 1000. The motor coil component 200 is formed by bending the transition portions 120a to 120d of the motor coil component 1000 as will be described later, and the pair of linear portions of each adjacent spiral portion is such that only one of the pair of linear portions overlaps. Is arranged.

  Further, the pair of overlapping linear portions are overlapped in the same winding direction. That is, the spiral portion 110α is adjacent to the spiral portion 110β, but the linear portion 112b of the spiral portion 110α and the linear portion 112d of the spiral portion 110β overlap to form an overlapping portion 130a. It does not overlap with the spiral. Further, the remaining straight portion 112c of the spiral portion 110β overlaps with the straight portion 112e of the spiral portion 110γ adjacent to the spiral portion 110β to form an overlapping portion 130b. Furthermore, the remaining straight portion 112f of the spiral portion 110γ overlaps with the straight portion 112h of the spiral portion 110δ adjacent to the spiral portion 110γ to form an overlapping portion 130c. The straight portion 112g of the remaining spiral portion 110δ does not overlap with other spiral portions, like the straight portion 112a.

  With such a configuration, the winding direction of the motor coil component 200 as a whole is unified in one direction as shown by the arrow in FIG.

  Here, a procedure for creating the motor coil component 200 from the motor coil component 1000 will be described with reference to FIGS.

  First, as shown in FIG. 3A, the motor coil is arranged such that the linear portion 112b of the spiral portion 110α and the linear portion 112d of the spiral portion 110β overlap each other when viewed from the front view of the motor coil assembly 100. The transition part 120a of the assembly 100 is bent.

  Next, as shown in FIG. 3 (b), the motor is arranged such that the linear portion 112 c of the spiral portion 110 β and the linear portion 112 e of the spiral portion 110 γ overlap each other when viewed from the front view of the motor coil assembly 100. The transition part 120b of the coil assembly 100 is bent. Further, as shown in FIG. 3C, the motor coil is arranged such that the straight portion 112f of the spiral portion 110γ and the straight portion 112g of the spiral portion 110δ overlap each other when viewed from the front view of the motor coil assembly 100. The transition part 120c of the assembly 100 is bent.

  FIG. 3 (d) shows a front view of the state where the step of FIG. 3 (c) is completed and an overlapping portion is formed in substantially the same manner as the state of FIG. 2 (a). Finally, the bent portions 120a to 120c are flattened by pressing to complete the motor coil component 200.

  Three motor coil components 200 as described above are created.

  Next, as shown in FIGS. 4 (a) and 4 (b), the three motor coil components 200 are arranged such that the principal surfaces of the spiral portions face each other and the crossing portions are on the same side. The motor coil assembly 300 is created so as to overlap. In the motor coil assembly 300, the three motor coil components 200 are stacked while shifting horizontally by one width of the linear portion, and as a result, as shown in FIG. When viewed from the front view direction of 200, the overlapping portions of the other two motor coil components are arranged one by one in the hollow portion 500 of the spiral portion of the uppermost motor coil. As shown in the plan view of FIG. 5B and the side view of FIG. 5C, the thickness of the motor coil assembly 300 is the thickness of three motor coil components 200.

  Next, as shown in the plan view of FIG. 6B and the side view of FIG. 6C, the hollow portion 500 of the spiral portion of the uppermost motor coil has an overlapping portion of the spiral portions of other motor coils. Fit one each. As a result, as shown in the sectional view of FIG. 6D taken along the line AA ′ in FIG. 6A, the thickness of the motor coil assembly 300 is the same as that of the motor coil component 200 by the overlapping portion. It becomes the thickness of the sheet. In addition, as shown to Fig.6 (a), the shape seen from the front of the motor coil component 200 does not change with Fig.5 (a).

  Finally, the motor coil component 300 is rolled into a cylindrical shape so that the transition portion becomes an edge portion, and a three-layer, four-pole motor coil 400 as shown in FIGS. 7 to 8 is completed. At this time, the motor coil component 300 has different thicknesses between the upper and lower ends and between them, but when rounded into a cylindrical shape, it is processed by printing pressure or the like so that all deviations in thickness appear on the outer wall side.

  Here, FIG. 7A is a front view of the motor coil 400, and FIG. 7B is a cross-sectional view taken along the line AA 'of FIG. 5A. FIG. 8A is a view showing a part of the inner wall of the motor coil 400, FIG. 8B is a plan view thereof, and FIG. 8C is taken along the line AA ′ of FIG. 8A. It is sectional drawing.

  With the processing shown in FIG. 6, in the cylindrical motor coil 400, one overlapping portion of the other spiral portion is fitted into the hollow portion of the spiral portion of each motor coil constituting the motor coil component 300. Therefore, as shown in FIG. 8C, the thickness of the wall surface of the central portion 410 is the thickness of the overlapping portion ((A) of FIG. 4) of the motor coil component 200. The overlapping portion has a thickness equivalent to two spiral portions, and the spiral portion is an alpha winding coil composed of a pair of opposed spiral coils, and thus has a thickness twice that of the wire. Therefore, the thickness of the wall surface of the central part 410 of the motor coil 400 is four times the thickness of the wire.

  As shown in FIG. 8B, in the motor coil 400, the upper and lower ends of the spiral portions of the motor coils constituting the motor coil component 300 are rounded so that the winding direction of the winding changes. Therefore, the motor coil component 300 has a thickness ((B) of FIG. 4), that is, three times the thickness of the overlapping portion of the motor coil component 200 and 12 times the thickness of the wire.

  Further, as shown in FIG. 7B, the overlapping portion of the motor coil 400 is bent by the pressure of the rounding process, but the outer shape of the coil is mainly formed by intermittently generating the gap 430 shown in black in the drawing. Is done.

  FIG. 7A shows an exaggerated thickness of the motor coil 400. FIG. The outer shape of the motor coil 400 in consideration of the actual aspect ratio is shown in FIG.

  The configuration of the motor coil 400 will be described in more detail with reference to FIGS. 7 and 10.

  FIG. 10A is a view showing a part of a cross section taken along the line AA ′ of FIG. 7B, and is a cross-sectional view of the wall surface of the motor coil 400. FIGS. 10B to 10C are views showing each motor coil component when the wall surface of the motor coil 400 is disassembled in units of 300 motor coil components. 10 (b) shows the S-phase motor coil component 300 arranged on the innermost circumference, and FIG. 10 (c) shows the T-phase motor coil component 300 arranged on the middle circumference. d) shows an R-phase motor coil component 300 arranged on the outermost periphery.

  As shown in FIG. 10A, the motor coil component 400 has different thicknesses at both end portions 420 and the central portion 410, but all the steps due to the change in thickness appear on the outer wall side, and the inner wall has a uniform curved surface. Is made. That is, there is no step on the inner wall of the cylindrical motor coil component 400.

  Further, as shown in FIGS. 10B to 10D, the S-phase motor coil component 300 does not reflect the change in the thickness of both ends 420, but the T-phase and R-phase motor coil components are not reflected. The straight portions of the 300 spiral portions are bent reflecting the changes in the thicknesses of both end portions 420 and the center portion 410 of the motor coil component 400, and form tapered portions 510 and 520, respectively. Note that the degree of change in the tapered portion increases as the motor coil component in the outer peripheral layer increases.

  The motor coil 400 having the above configuration has the following advantages compared to the conventional motor coil 2430 shown in FIG.

  As shown in FIG. 35, in the conventional motor coil 2430, when the wound conductors are formed into a cylindrical shape, the arrangement of the laminated conductors changes and the outer shape of the cross section collapses. By being formed obliquely along the cross section of the winding, a region 3600 indicated by a hatched portion in the drawing, which is made of a copper wire in which the current flows in the opposite direction, is formed in a region where the original current should flow in the forward direction. It entered and generated a magnetic field in the opposite direction, which caused a reduction in efficiency.

  On the other hand, in the motor coil 400 of the present embodiment, as shown in FIG. 6 (d), another wire rod is fitted to the central portion of the spiral portion formed by winding the wire rod in an alpha and edgewise manner. Since the winding shape is formed, the arrangement of the laminated wires does not change as shown in FIG. 8C even when it is formed into a cylindrical shape. Therefore, as shown in FIG. 11, the boundary of the magnetic field is formed radially from the radial direction of the cross section of the coil winding, that is, from the center of the cross section of the motor coil, and does not include a portion that is opposite to the generated magnetic field.

  Moreover, since the arrangement of the wire does not collapse, the thickness of the motor coil 400 is kept uniform. Furthermore, the thickness of the laminated wire is the thickness of the motor coil 400 as it is.

  With these improvements, the ideal magnetic field region distribution shown in FIG. 37 can be realized, and a highly efficient slotless motor can be realized. When the outer dimensions are the same, a 20% increase in torque can be realized as compared with the conventional motor coil 2460.

  Here, in FIGS. 12A to 12C, the straight line portion and the overlapping portion in each of the three layers of the motor coil component 300 constituting the motor coil 400 indicate which portion in the cross section of the motor coil 400 shown in FIG. It is shown whether it is arranged. In addition, the arrow in each figure shows the winding direction of a wire like FIG.

  As shown in each figure, the overlapping portions 620b (78a, 92b), 620e (80a, 94b), and 620h (82a, 96b) having an upward winding direction are obtained only from the wire having the upward winding direction in FIG. An upward area A is formed. The downward overlapping portions 620a (64a, 78b), 620d (66a, 80b), and 620g (68a, 82b) form a downward area B consisting only of a wire having a downward winding direction in FIG. The straight portions 610a (64b), 610b (106a), 610c (66d), 610d (108a), 610e (68b) and 610f (110a) having an upward winding direction form an upward area C similar to the upward area A. To do. The downward overlapping portions 620c (92a, 106b), 620f (94a, 108b), and 620i (96a, 110b) form a downward area D similar to the downward area B. In addition, the code | symbol shown in parenthesis in said description is a code | symbol which shows the arrangement | positioning area | region of the wire in FIG. . Further, only the upward area C is composed of a straight portion instead of an overlapping portion. However, since it has a configuration in which, for example, a straight portion 610a and a straight portion 610d are stacked vertically, it is regarded as substantially the same as the overlapping portion. Can do.

  The numbers in the parenthesis correspond to the numbers in FIG. 35 and FIG. 36, and the motor coil 400 of the present embodiment has a region opposite to the original pole as in the conventional motor coil 2430. It can be seen that has not entered.

(Embodiment 2)
In the first embodiment, a three-phase four-pole motor coil is created by laminating three motor coil components 300 each having four spiral portions that are alpha and edgewise wound. A three-phase two-pole motor coil is created by stacking three motor coil components having two spiral portions.

  FIG. 13A to FIG. 13C are diagrams showing the configuration of the motor coil component 700 of the present invention. As shown in FIG. 13 (a), the motor coil component 700 is configured by drawing a single wire, like the motor coil component 1000 of the first embodiment, and includes the spiral portions 710α and 710β, and the spiral portion. It is comprised from the crossing part 720 which connects between 710 (alpha) and 710 (beta).

  The spiral portions 710α and 710β are also configured by alpha winding and edgewise winding, and are configured by a pair of opposed spiral coils connected at the innermost peripheral portion. Therefore, the wire rod that has begun to be wound from one end and constitutes the spiral portion 710α has the other end reaching the outermost periphery of the spiral portion 710α and constitutes the transition portion 720a.

  Further, like the motor coil component 1000, the spiral portion 710α is wound so as to form a hollow portion 711, and linear portions S1b and S1a made of linearly extending wires facing each other across the hollow portion 711 are provided. The portion other than the straight portion is rounded, and the winding direction of the straight portion is reversed through this round. The spiral portion 710β has a similar configuration. The hollow portion 711 has a substantially oval shape, but the length on the short side, that is, the width, is substantially twice the width of the straight portion. Moreover, the arrow in a figure shows the direction of the winding which goes to the end of winding from the winding start of a wire, and in each spiral part, a pair of linear part has a mutually different winding direction.

  The motor coil components shown in FIGS. 13B and 13C have the same configuration as that shown in FIG.

  The motor coil components 700 as described above are overlapped so that the principal surfaces of the spiral portions face each other and the connecting portions are on the same side. At this time, the three motor coil components 700 are overlapped while shifting horizontally by one linear portion, and when viewed from the front view direction of the motor coil component 700, as shown in FIG. In the hollow part of the spiral part, the overlapping parts of the other two motor coil parts are fitted one by one to complete the motor coil part 750.

  Finally, the motor coil component 750 is rolled into a cylindrical shape so that the transition portion becomes an edge portion, and as shown in the front view of FIG. 15A and the cross-sectional view of FIG. The pole motor coil 800 is completed.

  Since the motor coil 800 is formed in a winding shape by fitting another wire to the center of the spiral portion formed by alpha winding and edgewise winding of the wire, similarly to the motor coil 400. Even when it is formed into a shape, the arrangement of the laminated wires does not change as shown in FIG. Therefore, as shown in FIG. 16, the boundary of the magnetic field is formed radially from the radial direction of the cross section of the coil winding, that is, from the center of the cross section of the motor coil, and does not include a portion that is opposite to the generated magnetic field. Thereby, high efficiency can be realized.

  13A to 13C, the straight portions S1a, T1a, and R1a having the downward winding direction in FIG. 16 form a downward area A ′ that includes only the wire having the downward winding direction. Further, in FIG. 16, the straight portions S2b, T2b, and R2b having the upward winding direction form an upward area B ′ composed only of the wire having the upward winding direction. Further, the straight portions S2a, T2a and R2a having the downward winding direction form a downward area C ′ similar to the downward area A ′ in FIG. Further, the straight portions S1b, T1b, and R1b having an upward winding direction form an upward area D ′ similar to the upward area B ′ in FIG.

(Embodiment 3)
In the first and second embodiments, the motor coil for the slotless motor is created. However, the motor coil component 1000 of the first embodiment as shown in FIG. 1 may be used as the motor coil for the linear motor. Good.

  The linear motor of this Embodiment is shown in the top view of Fig.17 (a), and the front view of FIG.17 (b). As shown in each figure, a linear motor 900 is a core base having a plurality of cores 920 arranged in a straight line, with the motor coil component 1000 of the first embodiment as a motor coil and fitted into the central portions 110α to 110δ. 910.

  In addition, as shown in the plan view of FIG. 18A and the front view of FIG. 18B, three motor coil components 1000 may be stacked and inserted. In this case, a three-phase four-pole linear motor can be obtained.

  Further, as shown in the plan view of FIG. 19A and the front view of FIG. 19B, the motor coil component 200 may be used as a motor coil for a linear motor.

  Furthermore, as shown in the plan view of FIG. 20A and the front view of FIG. 20B, the motor coil component 300 may be used as a motor coil for a linear motor.

  In each of the above embodiments, the motor coil component 1000 corresponds to the motor coil of the first invention, and the spiral portions 110α to 100δ and the spiral portion 710α and other equivalent spiral portions are the spirals of the first invention. The transition parts 120a to 120c and the transition part 720a and other equivalent transition parts correspond to the transition part of the first invention, and the hollow part 111 and the equivalent hollow part are the hollow parts of the first invention. It corresponds to the part. The straight portions 112a to 112h and the equivalent straight portions correspond to the straight portions of the first aspect of the present invention.

  Further, the overlapping portions 130a to 130c and the equivalent overlapping portion correspond to a straight line portion in which only one of the pair of straight line portions of the fourth aspect of the present invention overlaps.

  However, the present invention is not limited to the above embodiment.

  For example, in each of the above-described embodiments, the spiral portion is described as being alpha-winded and edge-wise wound. However, as the spiral portion of the present invention, the front view of FIG. As shown in the side view of b), a spiral part 1110 having a pair of straight parts 1112a and 1112b facing each other with the hollow part 1111 and the hollow part 1111 in between may be used, which is formed only by edgewise winding. . At this time, as shown in the front view of FIG. 22 (a) and the side view of FIG. 22 (b), the edge-wound wire is composed of two parallel lines 1200a and 1200b connected at the side edges. It may be what was done. This is due to the following reason. That is, when a rectangular wire is used as the wire, if the aspect ratio (aspect ratio) of the cross-sectional shape is increased, the wire may be wrinkled when the radius of the spiral portion is reduced. On the other hand, wrinkles can be prevented from occurring in each wire by using a plurality of rectangular wires having a small aspect ratio in parallel. In the drawing, two parallel lines 1200a and 1200b constitute an inner coil and an outer coil, respectively, but three or more parallel lines may be arranged in parallel.

  In each of the above embodiments, the wire has been described as a flat wire, but the wire of the present invention is not limited by the shape of the cross section. A round line, a square line, etc. may be sufficient. At this time, the spiral portion may be configured by only alpha winding.

  Moreover, although the horizontal width of the hollow portion 111 is set to two widths of the straight portion 112a, it may be increased by an integral multiple unit depending on the number of motor coil components to be stacked. The effect of the present invention can be obtained by setting at least the lateral width of the hollow portion = (the number of motor coil components 1000 to be laminated−1) × the lateral width of the linear portion 112a.

  In addition, the motor coil component 200 has been described as being created by bending the transition portions 120a to 120c of the motor coil component 1000. The motor coil component 200 is shown in the front view of FIG. 23 (a) and the side view of FIG. 23 (b). A plurality of such alpha-wound edgewise coils 1300 may be used, and the ends 1310a and 1310b of the coil 1300 may be connected later to assemble the configuration shown in FIG. Similarly, a plurality of edgewise coils shown in each drawing of FIG. 21 may be used alone.

  Further, in each of the above embodiments, the description has been made assuming that the spiral portions in each motor coil have the same winding direction, but the spiral portions of the present invention do not necessarily have the same winding direction. You don't have to. The winding direction may be alternately reversed via the crossover portion. Only a part of the plurality of spiral portions may be wound in the reverse direction. At this time, the spiral portions of the windings in the reverse direction may be disposed at arbitrary positions in the plurality of spiral portions, and may be disposed periodically or aperiodically. Moreover, although the arrangement | positioning of the transition part was also on the same straight line, you may make it connect spiral parts in arbitrary places arrangement | positioning.

  In each of the above embodiments, the present invention has been described as relating to a motor coil of a slotless motor or a linear motor. However, the slotless motor and the linear motor can be used as a generator in the same configuration. Therefore, the slotless motor and linear motor of the present invention can be implemented as a slotless generator and linear generator as they are, and this is also included in the present invention. Further, the motor coil of the present invention can be directly implemented as a motor coil for a slotless generator or a linear generator, and is included in the present invention.

  The motor coil and the motor coil manufacturing method according to the present invention have an effect capable of realizing, for example, a high-efficiency slotless motor. The motor coil used for the slotless motor, the linear motor, and the like, and the manufacturing method thereof Useful as such.

(A) Front view of motor coil component 1000 according to Embodiment 1 of the present invention (b) Side view of motor coil component 1000 according to Embodiment 1 of the present invention (A) Front view of motor coil component 200 according to Embodiment 1 of the present invention (b) Side view of motor coil component 200 according to Embodiment 1 of the present invention (A) The figure for demonstrating the manufacturing method of the motor coil component 200 by Embodiment 1 of this invention (b) The figure for demonstrating the manufacturing method of the motor coil component 200 by Embodiment 1 of this invention (c) ) A diagram for explaining a method for manufacturing motor coil component 200 according to the first embodiment of the present invention. (D) A diagram for describing a method for manufacturing motor coil component 200 according to the first embodiment of the present invention. (A) Front view of motor coil component 300 according to Embodiment 1 of the present invention (b) Side view of motor coil component 300 according to Embodiment 1 of the present invention (A) Front view of a part of the motor coil component 300 according to Embodiment 1 of the present invention (b) Plan view of a portion of the motor coil component 300 according to Embodiment 1 of the present invention (c) Implementation of the present invention Side view of a part of motor coil component 300 according to embodiment 1 (A) Front view at the time of processing a part of the motor coil component 300 according to the first embodiment of the present invention (b) Plan view at the time of processing a part of the motor coil component 300 according to the first embodiment of the present invention (c) ) Side view at the time of processing a part of the motor coil component 300 according to the first embodiment of the present invention. (A) Schematic front view of motor coil 400 according to Embodiment 1 of the present invention (b) Cross-sectional view of motor coil 400 according to Embodiment 1 of the present invention (A) Front view of a part of the motor coil 400 according to Embodiment 1 of the present invention (b) Plan view of a part of the motor coil 400 according to Embodiment 1 of the present invention (c) Embodiment 1 of the present invention Sectional drawing of a part of motor coil 400 by Front view of actual size of motor coil 400 according to Embodiment 1 of the present invention 1 is an exploded view of a motor coil 400 according to Embodiment 1 of the present invention. The figure for demonstrating arrangement | positioning of the wire in the motor coil 400 by Embodiment 1 of this invention. (A) The figure for demonstrating arrangement | positioning of the wire in the motor coil 400 by Embodiment 1 of this invention (b) The figure for demonstrating arrangement | positioning of the wire in the motor coil 400 by Embodiment 1 of this invention (c) ) Diagram for explaining arrangement of wire rods in motor coil 400 according to the first embodiment of the present invention. (A) Front view of motor coil component 700 according to Embodiment 2 of the present invention (b) Front view of motor coil component 700 according to Embodiment 2 of the present invention (c) Motor coil component according to Embodiment 2 of the present invention 700 front view Front view of motor coil component 750 according to Embodiment 2 of the present invention. (A) Schematic front view of motor coil 800 according to Embodiment 2 of the present invention (b) Cross-sectional view of motor coil 800 according to Embodiment 2 of the present invention The figure for demonstrating arrangement | positioning of the wire in the motor coil 800 by Embodiment 2 of this invention. (A) Top view of linear motor 900 according to Embodiment 3 of the present invention (b) Front view of linear motor 900 according to Embodiment 3 of the present invention (A) The top view of the other structural example of the linear motor by Embodiment 3 of this invention (b) The front view of the other structural example of the linear motor by Embodiment 3 of this invention (A) The top view of the other structural example of the linear motor by Embodiment 3 of this invention (b) The front view of the other structural example of the linear motor by Embodiment 3 of this invention (A) The top view of the other structural example of the linear motor by Embodiment 3 of this invention (b) The front view of the other structural example of the linear motor by Embodiment 3 of this invention (A) Front view of another configuration example of the spiral portion of the present invention (b) Side view of another configuration example of the spiral portion of the present invention (A) Front view of another configuration example of the spiral portion of the present invention (b) Side view of another configuration example of the spiral portion of the present invention (A) Front view of another configuration example of the spiral portion of the present invention (b) Side view of another configuration example of the spiral portion of the present invention (A) Front view of main part of conventional slotless motor (b) Side view of conventional slotless motor The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art The figure for demonstrating the manufacturing method of the motor coil by a prior art Cross-sectional view of a conventional motor coil The figure for demonstrating arrangement | positioning of the conducting wire in the motor coil by a prior art The figure for demonstrating arrangement | positioning of the conducting wire in the motor coil by a prior art Diagram showing ideal magnetic field distribution

Explanation of symbols

1000, 200, 300 Motor coil parts 110α to 110δ Spiral portion 111 Hollow portion 112a to 112h Straight portion 120a to 120c Crossing portion 130a to 130c Overlapping portion 400 Motor coil

Claims (15)

A plurality of spiral portions formed by winding a wire in a coil shape;
A connecting portion connecting the spiral portions,
Each of the spiral portions has a hollow portion at least in the center thereof and a pair of straight portions opposed to each other with the hollow portion interposed therebetween, and the hollow portion has a substantial width of the straight portion. A motor coil having an upper integer multiple gap.   The motor coil according to claim 1, wherein all of the plurality of spiral portions have the same winding direction.   The motor coil according to claim 1, wherein the crossing portions are arranged on the same straight line. The pair of linear portions of each of the adjacent spiral portions is arranged so that only one of the pair of linear portions overlaps each other,
The motor coil according to any one of claims 1 to 3, wherein the pair of overlapping linear portions have the same winding direction. The spiral portion is formed by alpha winding,
The motor coil according to any one of claims 1 to 4, wherein the transition portion is provided so as to connect outermost circumferences of the spiral portions.   The motor coil according to claim 1, wherein the spiral portion is formed by edgewise winding.   5. The motor coil according to claim 1, wherein the spiral portion and the crossing portion are configured by a single continuous wire.   The motor coil according to claim 1, wherein the wire is a flat wire. A motor coil formed by stacking a plurality of the motor coils according to any one of claims 1 to 8 so that main surfaces of the spiral portions are opposed to each other,
The plurality of motor coils overlap with each other while shifting by one width of the linear portion,
A motor coil in which, as viewed from the main surface side of the spiral portion, one straight portion of the spiral portion of another motor coil is housed in the hollow portion of the spiral portion of one motor coil.   A motor coil obtained by rolling the motor coil according to claim 9 into a cylindrical shape so that the crossing portion comes to an edge thereof. A method of manufacturing a motor coil according to claim 1,
From a single wire, comprising the step of creating a plurality of the spiral portion at a predetermined length interval,
A method of manufacturing a motor coil, wherein the wire has the predetermined length as the transition portion. A method of manufacturing a motor coil according to claim 4,
A step of creating a plurality of the spiral portions with a predetermined length interval from one wire,
The predetermined length portion of the wire is used as the transition portion, and the transition portion is bent so that only one of the pair of linear portions overlaps the pair of linear portions of the adjacent spiral portions. A step of arranging,
A method of manufacturing a motor coil, wherein a pair of overlapping linear portions have the same winding direction. A method of manufacturing a motor coil according to claim 1 or 4,
Creating the spiral portion from a single wire;
A method of manufacturing a motor coil, comprising: connecting a plurality of spiral portions with a wire having a predetermined length; and using the wire with the predetermined length as the transition portion. The motor coil according to any one of claims 1 to 4,
A linear motor comprising: a plurality of linearly arranged cores that fit into the central portions of the plurality of spiral portions of the motor coil. A motor coil according to claim 10;
A slotless motor comprising a cylindrical stator yoke into which the motor coil is inserted.

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