JP2005130676A - Manufacturing method of coil for electric equipment - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the manufacturing method of a coil for electric equipment by which the high-quality coil for electric equipment composed by edgewise winding is highly productively, simply, and inexpensively manufactured. <P>SOLUTION: The manufacturing method of a coil for electric equipment has a process I for cutting out a plurality of one turn square coils 11A-17A with a wire saw device 20 from block-shaped raw materials 11-17, which have through-holes 11E-17E formed along the center axis La of the raw material and notched parts 11B-17B continuously formed over the area from one end face of the raw material to the other end face by being made to communicate with the through-holes 11E-17E, and a process II in which mutual terminal ends 11D-17D and initial ends 11C-17C of the adjacent one turn square coils 11A-17A are overlapped with each other and joined into a spiral shape while laminating a plurality of the cut-out one turn square coils 11A-17A by successively deviating the positions of each notched part 11B-17B. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method of manufacturing a coil for an electric device used for a rotating device such as a motor and a generator, and an electric device such as a transformer.

  For example, as a coil for a motor, a so-called edgewise winding rectangular coil is known in which a conductor having a rectangular cross section is wound in a square shape with the short side of the cross section as a coil axis direction and spirally laminated in the coil axis direction. Yes.

  Such an edgewise-wound rectangular coil can increase the coil occupying ratio in the slot, and thus has an advantage that the motor efficiency can be improved and the motor can be reduced in size and weight.

  Conventionally, as a method of manufacturing the above-described rectangular coil, for example, as shown in FIG. 23, an arrow is applied to a flake-shaped cutting tool 102 rotating with respect to a hollow block-shaped material 101 made of extruded copper or aluminum. 24, the linear groove 103A is cut into the block-shaped material 101, and the groove 103A is processed at an equal pitch to obtain the required number of windings. Then, as shown in FIG. By changing the relative position of 101 and the cutting tool 102, a linear groove 103B is formed so that the processing start point and end point are obliquely connected to the previously processed groove 103A, and the rectangular coil 111 is formed. A method of manufacturing is known (see, for example, Patent Document 1).

JP-A-7-163100

  However, in the manufacturing method disclosed in Patent Document 1, when the linear groove 103B is cut, the processing start point and end point are obliquely connected to the previously processed groove 103A. Therefore, high machining accuracy is required. For this reason, there is a concern that the productivity is low and the cost is increased, and the start point and the end point of the processing of the groove 103B are not obliquely connected to the groove 103A, and a step is formed at the connecting portion. There is a concern that the quality of the coil may be reduced. Further, since the grooves 103A and 103B are processed by the cutting tool 102, the processing load is large, and the block-shaped material 101 may be deformed at the time of processing, and it is difficult to perform satisfactory grooving. Conversely, if the pitch between the grooves is increased to ensure the rigidity to withstand the processing load, the number of turns that can be formed is reduced, and it is feared that the desired performance as a coil cannot be exhibited.

  Accordingly, an object of the present invention made in view of such a point is to provide a method for manufacturing a coil for an electric device that can easily and inexpensively manufacture a coil for an electric device made of high-quality edgewise winding with a small coil interval. It is to provide.

  The invention of the method for manufacturing a coil for an electric device according to claim 1 that achieves the above object is characterized in that a conductor having a rectangular cross section is wound with the short side of the cross section as the coil axis direction and is laminated spirally in the coil axis direction. In the method for manufacturing a coil for an electrical device, a first roller and a second roller, each having a plurality of circumferential grooves formed on an outer peripheral surface thereof, and a wire between the circumferential grooves of the first roller and the second roller. And a wire row formed by a plurality of wire portions arranged in parallel between the first roller and the second roller, and the wire row is rotated by the first roller and the second roller. A wire saw device that is linearly moved together with the wire row that moves linearly of the wire saw device, a through hole formed along the central axis of the material, and a continuous material from one end surface to the other end surface that communicates with the through hole. The block-shaped material having a notch formed in this manner is relatively moved in a state where the linear motion direction of the wire row and the central axis of the material are substantially orthogonal to each other, and the block-like material is pressed against the wire row. A one-turn coil cutting step in which a plurality of one-turn coils are sliced in the presence of abrasive grains to cut out a plurality of one-turn coils divided into a start end and a terminal end by the notches, and the plurality of one-turn coils are divided into positions of the notches. And a joining step of superposing and welding or brazing the adjacent one-turn coils of adjacent one-turn coils while laminating them sequentially and joining them spirally.

  According to a second aspect of the present invention, in the method of manufacturing a coil for an electric device according to the first aspect, the one-turn coil cutout step has a plurality of externally visible prismatic shapes having the same outer dimensions and different formation positions of the cutout portions. A plurality of 1-turn rectangular coils are cut out by slicing each block-shaped material into equal thicknesses, and the above-mentioned joining step is performed by cutting a plurality of 1-turn rectangular coils cut from different block-shaped materials into each notch portion. It is characterized in that welding and brazing are performed by superimposing the end and the start of adjacent one-turn rectangular coils while sequentially laminating the positions.

  According to a third aspect of the present invention, in the method of manufacturing a coil for an electric device according to the first aspect, in the one-turn coil cutting step, an outer dimension and a formation position of the notch portion are different from each other. The same number of types of external prismatic block-shaped block materials as the number of turns are sliced into thicknesses having the same coil conductor cross-sectional area, and a plurality of 1-turn rectangular coils are cut out. A plurality of 1-turn rectangular coils cut out from a sheet material are welded by stacking the end and start ends of adjacent 1-turn rectangular coils while laminating the positions of the cutouts in order to form a truncated pyramid. Or it is characterized by brazing.

  According to a fourth aspect of the present invention, in the method of manufacturing a coil for an electric device according to the first aspect, the one-turn coil cutting step includes slicing a block-shaped material having an external appearance columnar shape into equal thicknesses, and The turn circular coil is cut out, and in the joining step, the ends and the start ends of the adjacent one turn circular coils are overlapped while laminating the cut out one turn circular coils while sequentially shifting the positions of the notches. And welding or brazing.

  According to a fifth aspect of the present invention, in the method for manufacturing a coil for an electric device according to the first aspect, the one-turn coil cut-out step is different in outer diameter size and has the same number as the number of turns of the electric device coil to be manufactured The cylindrical block-shaped material of the external appearance is sliced into thicknesses having the same coil conductor cross-sectional area, and a plurality of one-turn circular coils are cut out. The one-turn circular coil is welded or brazed by stacking the ends and the start ends of adjacent one-turn circular coils while sequentially laminating the positions of the notches and laminating them in a truncated cone shape. And

  According to a sixth aspect of the present invention, in the method of manufacturing a coil for an electric device according to the first aspect, the one-turn coil cut-out step includes a block-shaped material having a circular truncated conical shape in appearance, and a coil conductor cross-sectional area equal to each other The slice process is then performed to cut out a plurality of one-turn circular coils, and the joining step is performed by laminating the cut-out plurality of one-turn circular coils in a circular truncated cone shape by sequentially shifting the positions of the notches, The end and start ends of adjacent one-turn circular coils are overlapped and welded or brazed.

  The coil for electrical equipment according to claim 7 is a coil for electrical equipment, in which a conductor having a rectangular cross section is wound with the short side of the cross section as the coil axis direction and is spirally laminated in the coil axis direction. In the manufacturing method, the block-shaped material having a through-hole formed along the material central axis has an opening serving as a notch for dividing the start end and the end of the one-turn coil in communication with the through-hole. A plurality of opening forming steps formed along the central axis, a first roller and a second roller arranged in parallel with a plurality of circumferential grooves formed on the outer peripheral surface, and the respective circumferences of the first roller and the second roller A wire line formed by a plurality of wire portions arranged in parallel between the first roller and the second roller, the wire line being formed between the first roller and the second roller. With two rollers rotating A wire saw apparatus that linearly moves the wire array, and the wire array that linearly moves the wire saw apparatus and the block-shaped material in which the plurality of openings are formed, the linear motion direction of the wire array and the material central axis The block-shaped material is moved relative to each other in a substantially orthogonal state, the block-shaped material is pressed against the wire row, and the adjacent openings of the block-shaped material are sliced in the presence of abrasive grains, and the starting end and A one-turn coil cutting step of cutting out a plurality of one-turn coils having the cut-out portions that divide the terminal ends, and the one-turn coils adjacent to each other while laminating the plurality of one-turn coils by sequentially shifting the positions of the cut-out portions. And a joining step of joining the electrodes in a spiral manner by overlapping or welding or brazing the terminal end and the starting end.

  According to an eighth aspect of the present invention, in the method for manufacturing a coil for an electric device according to the seventh aspect, in the opening portion forming step, each of the plurality of opening portions has the same size in a block-shaped material having an external visual prism shape. In addition, the end and the start of adjacent one-turn coils cut out in the one-turn coil cut-out process are sequentially shifted so as to be superposed with each other, and the one-turn coil cut-out process includes an adjacent opening of the block-shaped material. A plurality of 1-turn rectangular coils each having the same thickness are cut out by slicing the gap, and the joining step is adjacent while sequentially laminating adjacent 1-turn rectangular coils cut out in the 1-turn coil cutting step. It is characterized by welding or brazing the end and start of the one-turn rectangular coil that overlap each other.

  According to a ninth aspect of the present invention, in the method of manufacturing a coil for an electric device according to the seventh aspect, in the opening forming step, the plurality of openings are formed on the block-shaped material having an external visual frustum shape and the one turn. As the outer dimensions of the block-shaped material are reduced so that the conductor cross-sectional areas of the one-turn coils cut out in the coil cutting process are equal, the dimensions in the material center axis direction are increased, and the end of the adjacent one-turn coil is increased. The one-turn coil cut-out step is formed by slicing between adjacent openings of the block-shaped material so that the conductor cross-sectional areas are equal and the outer dimensions are small. Cut out a plurality of 1-turn rectangular coils that become thicker and the joining process is cut in the 1-turn coil cutting process. While sequentially stacked adjacent one-turn square coils, characterized by welded or brazing the mutually overlapping end and the beginning of the adjacent one-turn square coils.

  According to the first aspect of the present invention, in the one-turn coil cutting step, the block-shaped material having a through hole and a notch portion that is continuously formed from one end surface of the material to the other end surface in communication with the through hole, Since a plurality of one-turn coils are cut out by slicing in the presence of abrasive grains with a wire saw device having a row, even if it is a block-like material made of aluminum or copper that has poor workability such as cutting, a plurality of one-turn The coil can be formed easily and efficiently. In addition, a plurality of 1-turn coils cut out in the 1-turn coil cut-out step are stacked in the joining step by laminating the positions of the adjacent cut-out portions while sequentially shifting the positions of the respective cut-out portions. Since welding or brazing is performed, it is possible to easily and inexpensively manufacture a coil for an electric device made of high-quality edge-wise winding with a narrow coil interval with high productivity.

  According to the second aspect of the present invention, in the one-turn coil cutting step, a plurality of block-shaped materials having the same external dimensions and different cut-off portion formation positions in the shape of the external visual prism are cut to the same thickness by the wire saw device. Since a plurality of cut one-turn rectangular coils are joined in the joining process, it is possible to easily mass-produce coils for electric appliances having an external visual prism shape made of high-quality edge-wise winding, which greatly reduces manufacturing costs. Can be expected.

  According to the invention of claim 3, in the one-turn coil cutting step, the external dimensions and the formation positions of the cutout portions are different from each other, and the same number of types of block-shaped material having the external visual prism shape as the number of turns of the coil for electrical equipment to be manufactured. In a joining process so that a plurality of one-turn rectangular coils cut out from these different block-shaped materials are formed into a truncated pyramid shape in appearance. Since they are joined together, it is possible to easily mass-produce a coil for an electric device having an external visual truncated pyramid shape made of high-quality edge-wise winding with a uniform coil conductor cross-sectional area, and a significant reduction in manufacturing cost can be expected.

  According to the invention of claim 4, in the one-turn coil cutting step, the block-shaped material having a columnar appearance is cut to the same thickness by the wire saw device, and the plurality of cut one-turn circular coils are joined in the joining step. In addition, it is possible to efficiently and easily manufacture a cylindrical coil for an electric device made of high-quality edgewise winding, and to easily mass-produce it.

  According to the invention of claim 5, in the one-turn coil cut-out step, the outer-diameter dimension is different, and the block-shaped material having the same number of types as the number of turns of the coil for electrical equipment to be manufactured is made into a block-shaped material having an outer appearance. High-quality edges with uniform coil conductor cross-sectional area, because the conductor cross-sectional areas are cut to the same thickness by a wire saw device, and multiple one-turn circular coils cut from these different block-shaped materials are joined in the joining process. It is possible to easily mass-produce a coil for electric equipment having a circular truncated conical shape made of Wise winding, and a significant reduction in manufacturing cost can be expected.

  According to the invention of claim 6, in the one-turn coil cutting step, a block-shaped material having a truncated cone shape in appearance is cut by a wire saw device to a thickness in which the conductor cross-sectional areas of the one-turn coil are equal to each other, and a plurality of the cut pieces Because the 1-turn circular coil is joined in the joining process, a coil for electrical equipment having a truncated conical shape made of high-quality edgewise winding with a uniform coil conductor cross-sectional area from one block-like material can be efficiently and simply And it becomes possible to manufacture at low cost.

  According to the invention of claim 7, in the opening forming step, since the plurality of openings are formed in the block-shaped material so as to communicate with the through holes, the opening is continuous from one end surface to the other end surface of the block-shaped material. There is nothing. Therefore, since the strength reduction of the block-shaped material can be prevented, in the one-turn coil cutting process, the deformation of the block-shaped material at the time of slicing by the wire saw device can be prevented, and the one-turn coil can be formed with high accuracy. . In addition, in the joining process, a plurality of one-turn coils are welded or brazed by superimposing the ends and the start ends of adjacent one-turn coils while laminating the positions of the respective cutout portions sequentially. It is possible to easily and inexpensively manufacture a coil for an electric device made of high-quality edge-wise winding with a narrow interval with high productivity.

  According to the invention of claim 8, in the opening forming step, the terminal end and the start end of the adjacent one-turn coil cut out in the subsequent one-turn coil cutting-out step overlap each other in the block-shaped material having an external visual prism shape, A plurality of openings having the same dimensions are formed by sequentially shifting, and the block-shaped material is cut into an equal thickness by a wire saw device in a one-turn coil cutting process, and the plurality of cut one-turn rectangular coils are bonded in the bonding process. Therefore, it is possible to efficiently manufacture a coil for an electric device having an external visual prism shape made of high-quality edgewise winding.

  According to the invention of claim 9, in the opening forming step, the conductor cross-sectional area of each one-turn coil cut out in the subsequent one-turn coil cutting-out step is equal to and adjacent to the block-shaped material having an external visual truncated pyramid shape. A plurality of openings are sequentially shifted so that the end and the start of the one-turn coil overlap each other, and this block-shaped material is cut out by a wire saw device in a one-turn coil cutting step, and the plurality of cut one-turn squares are cut out. Since the coils are joined in the joining step, a coil for electrical equipment having an external visual frustum shape made of high-quality edge-wise winding having a uniform coil conductor cross-sectional area can be efficiently manufactured from one block-shaped material.

  Embodiments of a method for manufacturing a coil for an electric device according to the present invention will be described below with reference to the drawings.

(First embodiment)
1 to 5 show a first embodiment, FIG. 1 is a diagram showing sequential steps, FIG. 2 is a perspective view of a coil for electrical equipment manufactured in the present embodiment, and FIG. 3 is a diagram. FIG. 4 is a perspective view showing a block-shaped material used in the present embodiment, and FIG. 5 is a perspective view showing a schematic configuration of the wire saw device.

  In this embodiment, as shown in FIG. 1, a one-turn coil cutting process I and a joining process II are sequentially performed, and a conductor having a rectangular cross section as shown in FIGS. The coil 10 for an electric device having an edgewise-wound appearance visual prism shape, which is wound in a rectangular shape as the axial direction L and spirally laminated in the axial direction L of the coil, is manufactured.

  That is, the coil 10 for electrical equipment manufactured in the present embodiment is held through a columnar core, and a coil in which flat conductors are spirally stacked in the axial direction of the core along the outer peripheral surface of the core. In this embodiment, there are a plurality of 1-turn rectangular coils 11A to 17A which are seven flat conductors. Each of the one-turn rectangular coils 11A to 17A is made of a conductive material such as copper or aluminum, and has a substantially rectangular through-hole through which a core having a rectangular cross-section and a columnar shape (not shown) is opened. The external shapes orthogonal to the direction L are the same square, and the cross-sectional areas of the respective one-turn rectangular coils 11A to 17A are the same, and the cross-sectional rectangles are larger in the width direction than in the thickness direction.

  A part of the one-turn rectangular coil 11A is divided into a start end 11C and a termination end 11D by a notch 11B. Similarly, each one-turn rectangular coil 12A-17A is divided into a starting end 12C-17C and a terminal end 12D-17D, a part of which is separated by a notch 12B-17B.

  The cutout portions 11B to 17B formed in the 1-turn rectangular coils 11A to 17A are arranged in a sequentially shifted manner as their positions shift from the 1-turn rectangular coil 11A to the 1-turn rectangular coil 17A in a stacked state. Further, when the one-turn rectangular coils 11A to 17A are sequentially stacked, the terminal end 11D of the adjacent one-turn rectangular coil 11A and the starting end 12C of the one-turn rectangular coil 12A are overlapped, that is, overlap each other, and sequentially turn one turn. End 12D of square coil 12A, start end 13C of 1-turn square coil 13A, end 13D of 1-turn square coil 13A, start end 14C of 1-turn square coil 14A, end 14D of 1-turn square coil 14A and start end of 1-turn square coil 15A 15C, the end 15D of the 1-turn square coil 15A, the start end 16C of the 1-turn square coil 16A, and the end 16D of the 1-turn square coil 16A and the start end 17C of the 1-turn square coil 17A are formed so as to be in contact with each other. .

  The 1-turn rectangular coils 11A to 17A formed in this way are formed by laminating the 1-turn rectangular coil 12A on the 1-turn rectangular coil 11A, and the end 11D of the 1-turn rectangular coil 11A and the 1-turn rectangular coil 12A. The start end 12C is joined by joining means 18 such as fillet welding or brazing in the notch 12B of the one-turn rectangular coil 12A.

  Similarly, a 1-turn square coil 13A is sequentially stacked on the 1-turn square coil 12A, and the end 12D of the 1-turn square coil 12A and the start end 13C of the 1-turn square coil 13A are joined by the joining means 18 in the notch 13B. The 1-turn square coil 14A is laminated on the 1-turn square coil 13A, and the end 13D of the 1-turn square coil 13A and the start end 14C of the 1-turn square coil 14A are joined by the joining means 18 in the notch 14B. A 1-turn square coil 15A is mounted on the 1-turn square coil 14A, and the end 14D of the 1-turn square coil 14A and the start end 15C of the 1-turn square coil 15A are joined by the joining means 18 in the notch 15B. A one-turn square coil 16A is laminated on the square coil 15A to form one coil. The end 15D of the rectangular coil 15A and the starting end 16C of the one-turn rectangular coil 16A are joined by the joining means 18 in the notch 16B, and finally the one-turn rectangular coil 17A is laminated on the one-turn rectangular coil 16A to make one turn. The terminal 16D of the rectangular coil 16A and the starting end 17C of the one-turn rectangular coil 17A are joined by the joining means 18 in the notch 17B, whereby a flat conductor formed by the one-turn rectangular coils 11A to 17A is continuously formed in a spiral shape. The starting end 11C of the 1-turn rectangular coil 11A and the terminal end 17D of the 1-turn rectangular coil 17A are open ends. At least the adjacent 1-turn square coil 11A and 1-turn square coil 12A, 1-turn square coil 12A and 1-turn square coil 13A, 1-turn square coil 13A and 1-turn square coil 14A, 1-turn square coil 14A and 1-turn square coil The coil 15A, the 1-turn square coil 15A and the 1-turn square coil 16A, and the 1-turn square coil 16A and the 1-turn square coil 17A are insulated.

  Hereinafter, each process of FIG. 1 which manufactures said coil 10 for electric devices is demonstrated in detail.

  First, prior to performing the one-turn coil cut-out step I, as shown in FIG. 4, the same number of types of block-shaped materials as the number of turns of the electrical equipment coil 10 to be manufactured, in this embodiment, one turn Block-shaped material 11 for forming the square coil 11A, block-shaped material 12 for forming the 1-turn square coil 12A, block-shaped material 13 for forming the 1-turn square coil 13A, and 1-turn square coil 14A are formed. Block-shaped material 14 for forming, block-shaped material 15 for forming 1-turn rectangular coil 15A, block-shaped material 16 for forming 1-turn rectangular coil 16A, and block for forming 1-turn rectangular coil 17A A total of seven types of block materials 11 to 17 together with the shape material 17 are used. In FIG. 4, three block-shaped materials 11, 12 and 17 are shown.

  Each of the block-shaped materials 11 to 17 is formed by extruding a conductive material such as copper or aluminum, and has a rectangular column shape with the same dimensions, and has a rectangular through hole 11E along the material center axis La at the center. To 17E, and are formed so as to have cutout portions 11B to 17B that communicate with the through holes 11E to 17E and continue from the one end surface of the material to the other end surface at different positions on one surface.

  In the present embodiment, in the one-turn coil cutting step I in FIG. 1, each of the block-shaped materials 11 to 17 is sliced into equal thicknesses in the presence of abrasive grains by the wire saw device 20 as shown in FIG. Then, a plurality of one-turn rectangular coils are cut out.

  Here, the wire saw device 20 includes a workpiece processing unit 21 and a workpiece holding unit (not shown). The workpiece processing unit 21 has a rotation center axis L1 and a rotation center axis L2 extending in parallel, and is rotatably arranged in parallel. One roller 22 and a second roller 23 are provided.

  On the outer periphery of the first roller 22, a first wire receiving groove 24-1, a second wire receiving groove 24-2, a third wire receiving groove 24-3 to a (n + 1) wire receiving groove 24- (n + 1). Similarly, on the outer periphery of the second roller 23, the first wire receiving groove 25-1, the second wire receiving groove 25-2, the third wire receiving groove 25-3 to the (n + 1) th ) A wire receiving groove 25- (n + 1) is formed. Each pitch between the first wire receiving groove 24-1 to the (n + 1) th wire receiving groove 24- (n + 1) formed on the first roller 22 and the first wire receiving groove formed on the second roller 23. Each pitch between the circumferential groove 25-1 and the (n + 1) th wire receiving groove 25- (n + 1) is equal to the thickness of each one-turn rectangular coil of the coil 10 for electrical equipment to be manufactured.

  Further, the wire saw device 20 includes a wire feeding reel and a wire take-up reel (not shown), and a cutting wire 26 made of a steel wire fed from the wire feeding reel is connected to the first wire receiving groove 24- of the first roller 22. 1 is wound around the first wire receiving groove 24-1, led to the first wire receiving groove 25-1 of the second roller 23, and further wound around the first wire receiving groove 25-1. To the second wire receiving groove 24-2 of the first roller 22 to be wound around. Similarly, the wire 26 continues from the second wire receiving groove 24-2 of the first roller 22 to the second wire receiving groove 25-2 of the second roller 23, and the third wire receiving groove 24 of the first roller 22. -3, the third wire receiving groove 25-3 of the second roller 23, the fourth wire receiving groove 24-4 of the first roller 22, and finally the (n + 1) wire receiving groove of the first roller 22. From 24- (n + 1), the (n + 1) -th wire receiving groove 25- (n + 1) of the second roller 23 is wound around the wire winding reel in order.

  Thereby, between the 1st roller 22 and the 2nd roller 23, orthogonally to the rotation center axis L1 and L2, the 1st wire surrounding groove 25-1 of the 2nd roller 23 of the wire 26 and the 1st roller 22 The first wire portion 26-1 stretched between the second wire receiving groove 24-2 and the second wire receiving groove 25-2 of the second roller 23 and the third wire receiving of the first roller 22. The second wire portion 26-2 stretched between the circumferential groove 24-3, the third wire circumferential groove 25-3 of the second roller 23, and the fourth wire circumferential groove 24-4 of the first roller 22. The third wire portion 26-3 stretched between the second roller 23 and the n-th wire receiving groove 25-n of the second roller 23 and the (n + 1) -th wire receiving groove 24 of the first roller 22. The n-th wire portions 26-n stretched between-(n + 1) are arranged at an equal pitch to form a wire row 26L. Is, the wire row 26L is adapted to reciprocate along with the forward and reverse rotation are repeated the first roller 22 and second roller 23.

  On the other hand, the work holding portion extends each block-shaped material 11 to 17 in the horizontal direction with the material center axis La parallel to the rotation center axis L1 of the first roller 22 and the rotation center axis L2 of the second rotor 23. It is supposed to be held in a state. Furthermore, the wire saw device 20 includes abrasive grain supply means (not shown) that sprays slurry containing abrasive grains onto the wire row 26L and supplies the abrasive grains to the wire row 26L.

  In the present embodiment, the block-shaped material 11 is held in the work holding unit of the wire saw device 20 described above, and the held block-shaped material 11 has the material center axis La as the rotation center axis L1 of the first roller 22 and the first material. 2 While maintaining a state extending in the horizontal direction parallel to the rotation center axis L2 of the rotor 23, the wire 23 is lowered and pressed against the wire row 26L, and the abrasive grains are supplied from the abrasive grain supply means to the wire row 26L. 26L is reciprocally linearly moved by forward and reverse rotation of the first roller 22 and the second roller 23 to slice, thereby cutting out a plurality of 1-turn rectangular coils 11A having the same thickness. The other block-shaped materials 12 to 17 are similarly sliced to cut out a plurality of 1-turn rectangular coils 12A to 17A having the same thickness.

  When processing the block-shaped material by the wire saw device 20, instead of lowering the block-shaped material, the first roller 22 and the second roller 23 may be raised to raise the wire row 26L. The wire row 26L may be raised simultaneously with lowering the shaped material. Further, in addition to the vertical movement of the block-shaped material and the wire row 26L, the block-shaped material may be rotated around the material central axis La so that each surface of the block-shaped material faces the wire row 26L.

  After slicing each of the block-shaped materials 11 to 17 and cutting out the plurality of 1-turn rectangular coils 11A to 17A as described above, the block-shaped materials 11 to 17 were then cut out in the joining process II. The one-turn rectangular coils 11A to 17A are collected one by one, and as described with reference to FIGS. 2 and 3, the positions of the notches 11B to 17B are sequentially shifted and stacked, The start end is overlapped and joined by joint means 18 such as fillet welding or brazing in the notch, and then the insulation processing is performed to manufacture the coil 10 for an electric device having an edge-wise-wound appearance visual prism shape.

  According to the present embodiment, in the one-turn coil cutting process I, the through hole 11E to 17E formed along the material center axis La and the through holes 11E to 17E communicate with each other from the material one end surface to the other end surface. The block-shaped materials 11 to 17 having a rectangular columnar appearance having the cutout portions 11B to 17B formed continuously are sliced in the presence of abrasive grains by the wire saw device 20 having the wire row 26L, and a plurality of one turn Since the rectangular coils 11A to 17A are cut out, the plurality of 1-turn rectangular coils 11A to 17A can be easily and efficiently produced even when the block-shaped materials 11 to 17 are made of aluminum or copper which is not good in workability such as cutting. Can be cut out.

  In addition, the block-shaped materials 11 to 17 have the same outer dimensions, and the notches 11B to 17B are formed at different positions. A plurality of one-turn rectangular coils 11A to 17A are respectively formed from these block-shaped materials 11 to 17. Since the coil 10 for electrical equipment is manufactured by cutting out each one-turn rectangular coil 11A to 17A as a set, the coil 10 for electrical equipment can be easily mass-produced from the set of block-shaped materials 11-17. .

  Further, in the joining process II, the 1-turn rectangular coils 11A to 17A are stacked while shifting the positions of the notches 11B to 17B, and the end and the start end of the adjacent 1-turn rectangular coils are overlapped and welded in the notch. Or since it brazes, each 1 turn square coil 11A-17A can be laminated | stacked, without being influenced by the junction part.

  Therefore, the end and the start of the adjacent one-turn square coil can be joined by any joining means 18 such as fillet welding or brazing in the notch, and the one-turn square coil is already joined at the lower side during joining. As a result, it is possible to prevent the adjacent one-turn square coil from being short-circuited by being coupled to the one-turn square coil, and thus producing a high-quality edge-wise-wound appearance visual column-shaped coil 10 for electrical equipment with a narrow coil interval. It can be easily manufactured with good performance, and a significant reduction in manufacturing cost can be expected. In addition, since the coil interval can be narrowed, generation of a gap between adjacent one-turn rectangular coils can be suppressed, excellent heat transfer can be achieved, good cooling can be obtained, and coil occupancy can be improved. Thus, it is possible to reduce the size and weight of the electric device.

  In this embodiment, in order to set the number of turns of the electric device coil 10 to be manufactured to 7 turns, the seven block-shaped materials 11 to 17 having different positions of the notches 11B to 17B are used. As apparent from FIG. 3, the 1-turn square coil 15A and the 1-turn square coil 13A, the 1-turn square coil 16A and the 1-turn square coil 12A, the 1-turn square coil 17A and the 1-turn square coil 11A are turned over. Since there is a relationship, the coil 10 for electrical equipment having a turn number of 7 turns can be manufactured from the four block-shaped materials 11 to 14 or 14 to 17.

(Second Embodiment)
FIGS. 6 to 8 show a second embodiment. FIG. 6 is a perspective view of a coil for an electric device manufactured according to the present embodiment. FIG. 7 is a view as viewed from an arrow B in FIG. It is a perspective view which shows the block-shaped raw material used by this Embodiment.

  In the present embodiment, similarly to the first embodiment, the one-turn coil cutting process I and the joining process II are sequentially performed, and a conductor having a rectangular cross section as shown in FIGS. Is wound in a rectangular shape with the coil axis direction L, and the edgewise-wound externally-viewed truncated pyramid-shaped coil for electrical equipment is wound in a spiral shape whose outer dimensions are sequentially increased or decreased as it moves in the coil axis direction L 30 is manufactured.

  That is, the coil 30 for electrical equipment manufactured in the present embodiment has 1-turn rectangular coils 31A to 37A made of a flat conductive material, and the 1-turn rectangular coils 31A to 37A are rectangular and rectangular, not shown. A substantially rectangular through-hole through which the core of the cross section passes is opened, and the outer shape perpendicular to the coil axis direction L is a square, and the cross-sectional rectangle is larger in the width direction than in the thickness direction.

  As in the first embodiment, each one-turn rectangular coil 31A to 37A is partly divided into start ends 31C to 37C and end points 31D to 37D by notches 31B to 37B. Each of these one-turn rectangular coils 31A to 37A has a dimension in the thickness direction that gradually increases as the transition from the one-turn rectangular coil 31A to the one-turn rectangular coil 37A, while a dimension in the width direction decreases in sequence. The conductor cross-sectional areas are equal.

  The cutout portions 31B to 37B formed in the 1-turn rectangular coils 31A to 37A are shifted from the 1-turn rectangular coil 31A to the 1-turn rectangular coil 37A in a state where the 1-turn rectangular coils 31A to 37A are sequentially stacked. And the end and the start of adjacent one-turn rectangular coils overlap each other and are in contact with each other.

  These 1-turn rectangular coils 31A to 37A are sequentially laminated, and the joining means 38 such as fillet welding or brazing where the end and the starting end of the adjacent 1-turn rectangular coils are notched in the same manner as in the first embodiment. The coil 30 for an electrical device having a frustum-shaped frustum-shaped appearance is wound by being continuously wound in a spiral shape with the start end 31C of the 1-turn rectangular coil 31A and the end 37D of the 1-turn rectangular coil 37A being open ends. Forming.

  In order to manufacture the coil 30 for electric equipment, as shown in FIG. 8, in order to cut out the block-shaped material of the same number as the number of turns of the coil 30 for electric equipment to be manufactured, in this embodiment, one turn square coil 31A. Block-shaped material 31, 1-turn square coil 32A for cutting out the block-shaped material 32, 1-turn square-shaped coil 33A for cutting out the block-shaped material 33, 1-turn square-shaped coil 34A for cutting out the block-shaped material 34, 1 turn A total of seven types of block-shaped materials 31 including a block-shaped material 35 for cutting out the rectangular coil 35A, a block-shaped material 36 for cutting out the one-turn rectangular coil 36A, and a block-shaped material 37 for cutting out the one-turn rectangular coil 37A. Use ~ 37. In FIG. 8, three block-shaped materials 31, 32 and 37 are shown.

  Each of the block-shaped materials 31 to 37 is formed by extruding a conductive material such as copper or aluminum, and has an external visual prism shape with different external dimensions, and a square with the same dimensions along the material central axis La at the center. Through-holes 31E to 37E, and are formed so as to have cutout portions 31B to 37B that communicate with the through-holes 31E to 37E and continue from one end surface of the material to the other end surface at different positions on one surface.

  Each of these block-shaped materials 31 to 37 is sliced in the presence of abrasive grains by the wire saw device 20 as shown in FIG. 5 in the one-turn coil cutting process I, and a plurality of one-turn rectangular coils 31A to 37A, respectively. Cut out. In the one-turn rectangular coils 31A to 37A, the pitch of the wire row 26L of the wire saw device 20 is set to be wider for the block-shaped material having a smaller outer dimension so that the cross-sectional areas of the respective coil conductors are equal. Make it thicker.

  Thereafter, in the joining step II of FIG. 1, as in the case of the first embodiment, the one-turn rectangular coils 31A to 37A cut out from the respective block-shaped materials 31 to 37 are collected one by one, and they are shown in FIG. As described with reference to FIG. 7, while laminating the positions of the notches 31B to 37B sequentially, the terminal ends of the adjacent one-turn rectangular coils are overlapped with each other and joined by the joining means 38 in the notches, The coil 30 for an electrical device having an edge-wise-wound appearance visual truncated pyramid shape is manufactured by insulation treatment.

  As described above, in this embodiment, in the one-turn coil cutout step I, the external dimensions and the formation positions of the cutout portions are different from each other, and the same number of types of external visual prism shapes as the number of turns of the electric device coil 30 to be manufactured The block-shaped materials 31 to 37 are cut out by the wire saw device 20 to the thicknesses where the coil conductor cross-sectional areas are equal to each other to form a plurality of 1-turn rectangular coils 31A to 37A, respectively, and each one-turn rectangular coil 31A to 31A- 37A is joined as in the first embodiment in the joining step II so as to form an external visual pyramid shape, so that the external visual pyramid made of high-quality edgewise winding with a uniform coil conductor cross-sectional area is obtained. The shaped electric device coil 30 can be easily mass-produced, and a significant reduction in manufacturing cost can be expected.

  Further, since the coil 30 for electric equipment has a truncated pyramid shape in appearance, for example, by using it as a stator coil of a motor, slots between the stator cores are left to each core leaving a minimum heat radiation path. Thus, the motor efficiency can be improved, and the motor can be reduced in size, weight and manufacturing cost. Similarly, when used for other electrical equipment, the electrical equipment can be reduced in size, weight and manufacturing cost.

(Third embodiment)
FIGS. 9 to 11 show a third embodiment. FIG. 9 is a perspective view of a coil for electrical equipment manufactured in the present embodiment. FIG. 10 is a view taken along the arrow C in FIG. It is a perspective view which shows the block-shaped raw material used by this Embodiment.

  In the present embodiment, a one-turn coil cutting step I and a joining step II are sequentially performed, and a conductor having a rectangular cross section as shown in FIGS. 9 and 10 is circular with the short side of the cross section being the coil axis direction L. A coil 40 for an electric device having a cylindrical shape in an outer appearance of an edgewise winding wound in a spiral manner is manufactured.

  That is, the electric device coil 40 manufactured in the present embodiment is held through the columnar core, and is a coil in which flat conductors are spirally stacked in the axial direction of the core along the outer peripheral surface of the core. In this embodiment, there are a plurality of 1-turn circular coils 41-1A to 41-7A which are seven flat conductors.

  Each of the one-turn circular coils 41-1A to 41-7A is made of a conductive material, and a circular through-hole having a substantially the same diameter through which a core having a circular cross-section (not shown) passes and opens in the core axis direction. The outer shape perpendicular to the coil axis direction L is a circle having substantially the same diameter, the cross-sectional rectangle is larger in the width direction than the thickness direction, and the cross-sectional areas of the respective coil conductors are equally formed. Each of the one-turn circular coils 41-1A to 41-7A is partially divided into start ends 41-1C to 41-7C and end ends 41-1D to 41-7D by cutout portions 41-1B to 41-7B. .

  These 1-turn circular coils 41-1A to 41-7A are stacked with the positions of the notches 41-1B to 41-7B being sequentially shifted, and the end of the adjacent 1-turn circular coils is the same as in the above embodiment. The starting end is joined by joining means 48 such as fillet welding or brazing in the notch, and the starting end 41-1C of the one-turn circular coil 41-1A and the terminal end 41-7D of the one-turn circular coil 41-7A are opened. A coil 40 for an electric device having a cylindrical shape in appearance is formed continuously in a spiral shape as an end.

  In the present embodiment, a block-shaped material 41 as shown in FIG. 11 is used to manufacture the above-described coil 40 for electric equipment. This block-shaped material 41 is formed by extruding a conductive material such as copper or aluminum, and has a cylindrical shape in appearance, and has a circular through hole 41E along the material central axis La at the center, Are formed so as to have a linearly continuous cutout 41B for forming cutouts 41-1B to 41-7B from one end surface of the material to the other end surface in communication with the through hole 41E.

  In the one-turn coil cutting step I, the block-shaped material 41 is sliced to the same thickness by the wire saw device 20 as shown in FIG. 5 to cut out a plurality of one-turn circular coils 41-1A to 41-7A. Thereafter, in the joining step II, the cut one-turn circular coils 41-1A to 41-7A are stacked while sequentially shifting the positions of the notches 41-1B to 41-7B as described in FIGS. Meanwhile, the end and start ends of the adjacent one-turn circular coils are overlapped and joined by the joining means 48 in the notch, and thereafter, insulation treatment is performed to manufacture the coil 40 for an electric device having an edgewise-wound cylindrical appearance. To do.

  As described above, in the present embodiment, in the one-turn coil cutting step I, the block-shaped material 41 having an external appearance cylindrical shape is cut to the same thickness by the wire saw device 20, and the plurality of cut one-turn circular coils 41- Since 1A to 41-7A are joined in the joining step II in the same manner as in the above-described embodiment, it is possible to manufacture a coil 40 for an electric device having a cylindrical shape in appearance and made of high-quality edge-wise winding. Moreover, when sequentially laminating the 1-turn circular coils 41-1A to 41-7A, the positions of the adjacent notches are easily shifted by rotating the laminated 1-turn circular coils around the coil axial direction L. Therefore, it is possible to efficiently and easily manufacture the coil 40 for an electric device having a cylindrical shape as viewed from the outside in an edgewise manner.

  Further, since the 1-turn circular coils 41-1A to 41-7A have the same dimensions, for example, by cutting a number of 1-turn circular coils corresponding to a plurality of coils 40 for electric equipment from one block-shaped material 41, It can also be easily mass-produced, thereby making it possible to further reduce manufacturing costs.

(Fourth embodiment)
FIGS. 12 to 14 show a fourth embodiment. FIG. 12 is a perspective view of a coil for an electric device manufactured according to the present embodiment. FIG. 13 is a view taken along arrow D in FIG. It is a perspective view which shows the block-shaped raw material used by this Embodiment.

  In the present embodiment, the one-turn coil cutting process I and the joining process II are sequentially performed, and a conductor having a rectangular cross section as shown in FIGS. A coil 50 for an electric device having a frustoconical appearance with an edgewise winding is manufactured by winding and spirally laminating the outer diameter dimension sequentially increasing or decreasing as it moves in the coil axial direction L.

  That is, the electric device coil 50 includes 1-turn circular coils 51A to 57A made of a flat conductive material, and the 1-turn circular coils 51A to 57A are substantially column-shaped cores having a circular cross section that are not shown. A circular through-hole is opened, and the outer shape perpendicular to the coil axis direction L is circular and is formed in a cross-sectional rectangle having a larger dimension in the width direction than that in the thickness direction. Each of the one-turn circular coils 51A to 57A is partially divided into start ends 51C to 57C and end points 51D to 57D by notches 51B to 57B, as in the above embodiment. Each of these one-turn circular coils 51A to 57A increases in size in the thickness direction sequentially as it moves from the one-turn circular coil 51A to the one-turn circular coil 57A, while the dimension in the width direction decreases in sequence. The conductor cross-sectional areas are equal.

  As these 1-turn circular coils 51A to 57A are stacked while sequentially shifting the positions of the notches 51B to 57B, the end and the start of the adjacent 1-turn circular coils are filled in the notches as in the above embodiment. Joined by joining means 58 such as welding or brazing and continuously wound spirally with the starting end 51C of the one-turn circular coil 51A and the terminal end 57D of the one-turn circular coil 57A opened as an open end cone A trapezoidal electric device coil 50 is formed.

  In order to manufacture the electric device coil 50, as shown in FIG. 14, the same number of types of block-shaped materials as the number of turns of the electric device coil 50 to be manufactured, in this embodiment, one-turn circular coils 51A to 57A A total of seven types of block-shaped materials 51 to 57 for cutting out are used. In FIG. 14, three block-shaped materials 51, 52 and 57 are shown.

  Each of the block-shaped materials 51 to 57 is formed by extruding a conductive material such as copper or aluminum, and has a cylindrical shape in appearance with different outer diameters. The central portion has the same diameter along the material central axis La. It has through-holes 51E to 57E, and is formed on the outer peripheral surface so as to have notches 51B to 57B communicating with the through-holes 51E to 57E and continuing from one end surface of the material to the other end surface.

  Each of the block-shaped materials 51 to 57 is sliced by the wire saw device 20 as shown in FIG. 5 in the one-turn coil cutting process I, and a plurality of one-turn circular coils 51A to 57A are cut out. In the one-turn circular coils 51A to 57A, the pitch of the wire rows 26L of the wire saw device 20 is set wider for the block-shaped material having a smaller outer diameter so that the cross-sectional areas of the respective coil conductors are equal, and the slice thickness is set. Make it thicker.

  Thereafter, in the joining step II, as in the case of the first and second embodiments, the one-turn circular coils 51A to 57A cut out from the respective block-shaped materials 51 to 57 are collected one by one, and the notches 51B to 57B are collected. While laminating the positions one after another, the ends and the start ends of adjacent one-turn rectangular coils are overlapped and joined by the joining means 58 in the notch, and then subjected to insulation treatment to form a frustoconical external appearance of edgewise winding. The coil 50 for electric equipment is manufactured.

  As described above, in the one-turn coil cutting process I, the outer diameter dimensions are different from each other, and the block-shaped materials 51 to 57 having the same number of types as the number of turns of the electric device coil 50 to be manufactured are used as coil conductors. A plurality of 1-turn circular coils 51A to 57A are formed by cutting with the wire saw device 20 to have the same cross-sectional area, and each of the 1-turn circular coils 51A to 57A is used as a set. In this way, since the joining is performed in the joining step II, it is possible to easily mass-produce the coil 50 for an electric device having a circular frustoconical shape made of high-quality edge-wise winding with a uniform coil conductor cross-sectional area, and manufacturing cost Can be expected to be significantly reduced. Moreover, when the 1-turn circular coils 51A to 57A are sequentially laminated, they are circular, so that the 1-turn circular coil to be laminated is centered on the coil axial direction L as in the case of the third embodiment. The position of the adjacent notch part can be easily shifted by rotating to. Therefore, the coil 50 for an electric device having a frustoconical shape with an edgewise winding can be manufactured efficiently, simply and inexpensively.

(Fifth embodiment)
15 to 17 show a fifth embodiment. FIG. 15 is a perspective view of a coil for electrical equipment manufactured in the present embodiment. FIG. 16 is a view as viewed from an arrow E in FIG. It is a perspective view which shows the block-shaped raw material used by this Embodiment.

  In the present embodiment, similarly to the fourth embodiment, a one-turn coil cutting step I and a joining step II are sequentially performed, and a conductor having a rectangular cross section as shown in FIGS. An electric device having a truncated cone shape in the appearance of edgewise winding, in which a short side is wound in a circular shape with a coil axis direction L, and the outer diameter dimension is sequentially increased or decreased as the coil axis direction L is shifted. The coil 60 for manufacture is manufactured.

  This electric device coil 60 is the same as the electric device coil 50 manufactured in the fourth embodiment, and has 1-turn circular coils 61-1A to 61-7A made of a flat conductive material. Each of the one-turn circular coils 61-1A to 61-7A is partially divided into start ends 61-1C to 61-7C and end ends 61-1D to 61-7D by notches 61-1B to 61-7B. Along with the transition from the one-turn circular coil 61-1A to the one-turn circular coil 61-7A, the dimension in the thickness direction sequentially increases, while the dimension in the width direction decreases successively, so that the cross-sectional areas of the respective coil conductors are equal. It has become.

  These one-turn circular coils 61-1A to 61-7A are stacked by sequentially shifting the positions of the notches 61-1B to 61-7B, and the end and the start of the adjacent one-turn circular coils are fillets in the notches. Joined by joining means 68 such as welding or brazing, it is continuous in a spiral shape with the starting end 61-1C of the one-turn circular coil 61-1A and the terminal end 61-7D of the one-turn circular coil 61-7A as an open end. The coil 60 for electric equipment having a truncated cone shape in appearance is formed.

  In the present embodiment, a block-shaped material 61 as shown in FIG. The block-shaped material 61 is formed of a conductive material such as copper or aluminum, and has a circular truncated conical shape. The central portion has a circular through hole 61E along the material central axis La at the center. The surface is formed so as to have a linearly continuous cutout portion 61B for forming the cutout portions 61-1B to 61-7B from the one end surface of the material to the other end surface in communication with the through hole 61E.

  This block-shaped material 61 is sliced by the wire saw device 20 in the one-turn coil cutting step I, and a plurality of one-turn circular coils 61-1A to 61-7A are cut out. Note that the one-turn circular coils 61-1A to 61-7A have the wire diameter of the wire saw device 20 as the outer diameter size of the block-shaped material 61 having a circular truncated conical shape is reduced so that the cross-sectional areas of the respective coil conductors are equal. Increasing the pitch of the row 26L increases the slice thickness.

  Thereafter, in the joining process II, the cut one-turn circular coils 61-1A to 61-7A are stacked while sequentially shifting the positions of the cutout portions 61-1B to 61-7B in the arrangement order when being cut. Then, the end and start ends of the adjacent one-turn circular coils are overlapped and joined by the joining means 68 in the notch, and then insulated to manufacture the coil 60 for an electric device having an edgewise-wound appearance frustoconical shape. .

  As described above, in the present embodiment, in the one-turn coil cutting step I, the block-shaped material 61 having a circular truncated conical shape is cut by the wire saw device 20 to have a thickness equal to each of the coil conductor cross-sectional areas and cut out. Since the plurality of 1-turn circular coils 61-1A to 61-7A are joined in the joining step II in the same order as in the above-described embodiment in the arrangement order when they are cut out, the cross-sectional area of the coil conductor from one block-like material 61 It is possible to efficiently manufacture the coil 60 for electric equipment having a circular truncated conical shape made of high-quality edge-wise winding. Moreover, when the 1-turn circular coils 61-1A to 61-7A are sequentially stacked, they are circular, and the 1-turn circular coils to be stacked are arranged in the coil axial direction as in the case of the fourth embodiment. By rotating around L, the positions of the adjacent notches can be easily shifted, and therefore can be manufactured easily and inexpensively.

(Sixth embodiment)
FIGS. 18 to 20 show a sixth embodiment, FIG. 18 is a diagram showing sequential steps, FIG. 19 is a side view of a coil for electrical equipment manufactured in the present embodiment, and FIG. It is a perspective view which shows the block-shaped raw material processed at the 18 opening part formation process.

  In this embodiment, as shown in FIG. 18, an opening forming step V, a one-turn coil cutting step VI, and a joining step VII are sequentially performed, and a conductor having a rectangular cross section as shown in FIG. A coil 70 for an electric device having an edge-wise winding shape and an external visual prism shape, in which a side is wound in a rectangular shape with a coil axis direction L and spirally stacked in the coil axis direction L, is manufactured.

  That is, this electric device coil 70 is the same as the electric device coil 10 manufactured in the first embodiment, and has 1-turn rectangular coils 71-1A to 71-7A made of a flat conductive material. Each of the 1-turn rectangular coils 71-1A to 71-7A is partly divided into start ends 71-1C to 71-7C and end ends 71-1D to 71-7D by cutout portions 71-1B to 71-7B. The cutout portions 71-1B to 71-7B are in a state in which the 1-turn rectangular coils 71-1A to 71-7A are sequentially stacked, and the positions thereof are from the 1-turn rectangular coil 71-1A to the 1-turn rectangular coil 71-7A. Are arranged so as to be sequentially shifted, and are formed so that the end and the start of adjacent one-turn rectangular coils overlap each other.

  While these 1-turn rectangular coils 71-1A to 71-7A are sequentially laminated, the end and the starting end of adjacent 1-turn rectangular coils are joined by joining means 78 such as fillet welding or brazing in the notch, A coil 70 for electric appliances having an outward-viewing prismatic shape that is spirally continuous with the starting end 71-1C of the one-turn rectangular coil 71-1A and the terminal end 71-7D of the one-turn rectangular coil 71-7A as an open end is formed. Yes.

  In the present embodiment, in order to manufacture the electrical device coil 70 described above, first, in the opening forming step V, as shown in FIG. The end and start ends of adjacent one-turn coils formed in the subsequent one-turn coil cutting process VI are superposed on one surface of a block-shaped material 71 made of a conductive material such as copper or aluminum having a square through hole 71E. As possible, openings 71-1F to 71-7F having the same dimensions for forming the notches 71-1B to 71-7B are formed in communication with the through holes 71E and shifted. Note that the openings 71-1F to 71-7F can be formed by a known processing method capable of drilling such as electric discharge processing or beam processing.

  Thereafter, in the one-turn coil cutting step VI, the wire saw device 20 as shown in FIG. 5 is used to slice between adjacent openings of the block-shaped material 71 (shown by broken lines in FIG. 20), and the cut-out portions 71- A plurality of 1-turn rectangular coils 71-1A to 71-7A having the same thickness divided by 1B to 71-7B are cut out.

  Next, in the joining step VII, the cut 1-turn rectangular coils 71-1A to 71-7A are stacked by sequentially shifting the positions of the cutout portions 71-1B to 71-7B in the arrangement order when being cut. However, the end and start ends of the adjacent one-turn rectangular coils are overlapped and joined by the joining means 78 in the notch, and thereafter, insulation treatment is performed to manufacture an edgewise-wound appearance visual prism-shaped coil 70 for electrical equipment. .

  Thus, in this Embodiment, in the opening part formation process V, the opening for forming the notch parts 71-1B-71-7B in one surface of the block-shaped raw material 71 of the external appearance prismatic column shape which has the through-hole 71E. Since the portions 71-1F to 71-7F are formed by shifting, the openings 71-1F to 71-7F do not continue from one end surface to the other end surface of the block-shaped material 71. Therefore, since the strength reduction of the block-shaped material 71 can be prevented, in the one-turn coil cutting process VI, the deformation of the block-shaped material 71 at the time of slicing by the wire saw device 20 can be prevented, and the one-turn rectangular coils 71-1A to 71-71. -7A can be cut out with high accuracy. Moreover, in the joining step VII, the cut-out 1-turn rectangular coils 71-1A to 71-7A are arranged in the arrangement order when they are cut out, as in the case of the above-described embodiment. Since the end and the start end are overlapped and joined by the joining means 78 in the cutout portion, the external-appearance prismatic electric coil 70 made of high-quality edgewise winding is efficiently manufactured from one block-like material 71. Can do.

(Seventh embodiment)
FIGS. 21 and 22 show a seventh embodiment, FIG. 21 is a side view of the coil for an electric device manufactured in the present embodiment, and FIG. 22 is a perspective view showing a block material processed in the opening forming step. FIG.

  In the present embodiment, as in the sixth embodiment, the opening portion forming step V, the one-turn coil cutting step VI, and the joining step VII are sequentially performed to form a conductor having a rectangular cross section as shown in FIG. Edge-wise wound external visual frustum that is wound in a rectangular shape with the short side of the coil as the coil axis direction L and spirally laminated with the outer dimensions increasing or decreasing sequentially as it moves in the coil axis direction L The electric device coil 80 having a shape is manufactured.

  That is, this electric device coil 80 is the same as the electric device coil 30 manufactured in the second embodiment, and has 1-turn rectangular coils 81-1A to 81-7A made of a flat conductive material. Each of the one-turn rectangular coils 81-1A to 81-7A is partially divided into start ends 81-1C to 81-7C and end portions 81-1D to 81-7D by cutout portions 81-1B to 81-7B. While the dimension in the thickness direction increases sequentially as the transition from the one-turn rectangular coil 81-1A to the one-turn rectangular coil 81-7A, the dimension in the width direction decreases sequentially, and the respective coil conductor cross-sectional areas become equal. Yes.

  Further, the cutout portions 81-1B to 81-7B of the 1-turn rectangular coils 81-1A to 81-7A are in a state where the 1-turn rectangular coils 81-1A to 81-7A are sequentially stacked, and the positions thereof are 1-turn rectangular coils. As the transition from 81-1A to 1-turn rectangular coil 81-7A is made, the arrangement is sequentially shifted, and the end and the starting end of adjacent 1-turn rectangular coils are overlapped and contacted.

  As these 1-turn rectangular coils 81-1A to 81-7A are sequentially laminated, the end and the starting end of the adjacent 1-turn rectangular coils are fillet welded or brazed in the notch as in the second embodiment. Are joined by the joining means 88 and continuously wound in a spiral shape with the starting end 81-1C of the one-turn rectangular coil 81-1A and the terminal end 81-7D of the one-turn rectangular coil 81-7A as the open ends. A coil 80 for electric equipment having an external visual frustum shape is formed.

  In the present embodiment, in order to manufacture the above-described coil 80 for electric equipment, first, in the opening forming step V, as shown in FIG. Opening portions 81-1F to 81-7F for forming the notches 81-1B to 81-7B are formed on one surface of the block-shaped material 81 made of a conductive material such as copper or aluminum having a square through hole 81E. As in the case of the sixth embodiment, the through hole 81E is formed by electrical discharge machining or the like.

  The openings 81-1F to 81-7F are block-shaped materials so that the cross-sectional areas of the coil conductors of the one-turn rectangular coils 81-1A to 81-7A cut out in the subsequent one-turn coil cutting-out step VI are equal. As the external dimensions of 81 are reduced, the dimensions in the direction of the material center axis La are increased, and the adjacent one-turn rectangular coils are sequentially shifted so that the terminal ends and the starting ends thereof overlap each other.

  Thereafter, in the one-turn coil cutting step VI, the wire saw device 20 slices between adjacent openings of the block-shaped material 81 (shown by broken lines in FIG. 22), and divides at the notches 81-1B to 81-7B, respectively. A plurality of 1-turn rectangular coils 81-1A to 81-7A having the same coil conductor cross-sectional area are cut out. At this time, the pitch of the wire rows 26L of the wire saw device 20 is set so as to increase as the outer dimensions become smaller, as in the case of the fourth embodiment.

  Next, in the joining step VII, the cut 1-turn rectangular coils 81-1A to 81-7A are stacked by sequentially shifting the positions of the notches 81-1B to 81-7B in the arrangement order when they are cut. However, the terminal end and the start end of the adjacent one-turn rectangular coil are overlapped and joined by the joining means 88 in the notch, and thereafter, insulation treatment is performed to manufacture the coil 80 for an electric device having an edgewise-wound appearance visual truncated pyramid shape. To do.

  As described above, in the present embodiment, in the opening forming step V, the block-shaped material 81 having the externally-viewed truncated pyramid shape is provided with the notches 81-1B to 81- of the 1-turn rectangular coils 81-1A to 81-7A. Since the openings 81-1 </ b> F to 81-7 F for forming 7 </ b> B are formed sequentially shifted, the strength reduction of the block-shaped material 81 can be reduced. Accordingly, in the one-turn coil cutting step VI, the deformation of the block-shaped material 81 at the time of slicing by the wire saw device 20 can be prevented, so that the one-turn rectangular coils 81-1A to 81-7A can be cut out with high accuracy.

  Further, in the joining step VII, the one-turn rectangular coils 81-1A to 81-7A are joined in the arrangement order when they are cut out in the same manner as in the sixth embodiment. It is possible to efficiently manufacture a coil 80 for an electric device having an external visual truncated pyramid shape made of high-quality edge-wise winding having a uniform coil conductor cross-sectional area suitable for use in a stator coil.

  In addition, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the meaning of invention. For example, the appearance of the electrical device coil to be manufactured is not limited to the prism shape, the truncated pyramid shape, the columnar shape, the truncated cone shape, and the electrical device coil such as an elliptical column shape and an elliptical truncated cone shape. You can also Moreover, the number of turns of the coil for electrical equipment to be manufactured is not limited to 7 turns, and can be any number of turns.

It is a figure which shows the sequential process in 1st Embodiment of this invention. It is a perspective view of the coil for electric equipments manufactured by a 1st embodiment. FIG. 3 is a view as seen from an arrow A in FIG. 2. It is a perspective view which shows the block-shaped raw material used in 1st Embodiment. Similarly, it is a perspective view which shows schematic structure of a wire saw apparatus. It is a perspective view of the coil for electric equipments manufactured by the 2nd embodiment of the present invention. It is a B arrow view of FIG. It is a perspective view which shows the block-shaped raw material used in 2nd Embodiment. It is a perspective view of the coil for electric equipments manufactured by the 3rd embodiment of the present invention. It is C arrow line view of FIG. It is a perspective view which shows the block-shaped raw material used in 3rd Embodiment. It is a perspective view of the coil for electric equipment manufactured by 4th Embodiment of this invention. It is D arrow line view of FIG. It is a perspective view which shows the block-shaped raw material used in 4th Embodiment. It is a perspective view of the coil for electric equipment manufactured by 5th Embodiment of this invention. It is E arrow line view of FIG. It is a perspective view which shows the block-shaped raw material used in 5th Embodiment. It is a figure which shows the sequential process in 6th Embodiment of this invention. It is a side view which shows the coil for electric equipments manufactured by 6th Embodiment. It is a perspective view which shows the block-shaped raw material processed at the opening part formation process by 6th Embodiment. It is a side view which shows the coil for electric equipments manufactured by 7th Embodiment of this invention. It is a perspective view which shows the block-shaped raw material processed at the opening part formation process by 7th Embodiment. It is a figure for demonstrating an example of the manufacturing method of the conventional square coil. Similarly, it is a figure for demonstrating the manufacturing method of the conventional square coil.

Explanation of symbols

I 1-turn coil cut-out process II Joining process L Coil axial direction La Material central axis 10 Coil for electrical equipment 11-17 Block-shaped material 11A-17A 1-turn rectangular coil 11B-17B Notch 11C-17C Start end 11D-17D End 11E- 17E Through-hole 18 Joining means 20 Wire saw device 22 1st roller 23 2nd roller 26L Wire row 30 Electric device coil 31-37 Block material 31A-37A 1 turn square coil 31B-37B Notch 31C-37C Start end 31D-37D Termination 31E-37E Through-hole 38 Joining means 40 Coil for electrical equipment 41 Block material 41-1A-41-7A 1 turn circular coil 41B, 41-1B-41-7B Notch 41-1C-41-7C Beginning end 41- 1D to 41-7D Termination 41 Through hole 48 Joining means 50 Coil for electric equipment 51 to 57 Block material 51A to 57A 1 turn circular coil 51B to 57B Notch 51C to 57C Start end 51D to 57D End 51E to 57E Through hole 58 Joining means 60 Coil for electric equipment 61 -1A to 61-7A 1-turn circular coil 61B, 61-1B to 61-7B Notch 61-1C to 61-7C Start 61-1D to 61-7D End 61E Through-hole 68 Joining means V Opening formation process VI 1 Turn coil cutting process VII Joining process 70 Coil for electric equipment 71 Block material 71-1A to 71-7A 1-turn rectangular coil 71-1B to 71-7B Notch part 71-1C to 71-7C Starting end 71-1D to 71- 7D terminal 71E through-hole 71-1F-71-7F opening part 78 joining means 8 Coil for electrical equipment 81 Block material 81-1A to 81-7A 1-turn rectangular coil 81-1B to 81-7B Notch 81-1C to 81-7C Start end 81-1D to 81-7D End 81E Through hole 81-1F ~ 81-7F Opening 88 Joining means

Claims (9)

In a method for manufacturing a coil for an electric device, in which a conductor having a rectangular cross section is wound with its short cross section as a coil axis direction and is laminated spirally in the coil axis direction,
A first roller and a second roller, each having a plurality of circumferential grooves formed on the outer circumferential surface, and a wire wound between the circumferential grooves of the first roller and the second roller, A wire saw formed by a plurality of wire portions arranged in parallel with the second roller, and using a wire saw device that linearly moves the wire row together with the rotation of the first roller and the second roller, A block having a wire movement of the wire saw device in a straight line, a through hole formed along the material central axis, and a notch formed continuously from the one end surface of the material to the other end surface in communication with the through hole. Is moved relative to each other in a state in which the linear motion direction of the wire row and the central axis of the wire are substantially perpendicular to each other, and the block-like material is pressed against the wire row and sliced in the presence of abrasive grains. Shi 1 and turn coil cutout step of cutting a plurality of one-turn coil is divided into beginning and the end by the notch,
A joining step of joining the plurality of one-turn coils in a spiral manner by laminating the positions of the respective cutout portions sequentially and laminating the ends and the start ends of the adjacent one-turn coils and welding or brazing them. A method for manufacturing a coil for an electric device, comprising: The 1-turn coil cutting process
Slicing a plurality of block-shaped materials having the same external dimensions and different appearance-viewing prismatic shapes with different cut-out formation positions into equal thicknesses to cut out a plurality of one-turn rectangular coils,
The joining process
A plurality of one-turn rectangular coils cut from different block-shaped materials are stacked with the positions of the respective cutouts being sequentially shifted, and the ends and starting ends of adjacent one-turn rectangular coils are overlapped and welded or brazed. The manufacturing method of the coil for electrical devices of Claim 1 characterized by the above-mentioned. The 1-turn coil cutting process
The external dimensions and the formation positions of the notches differ from each other, and the same number of types of block-shaped materials in the appearance-viewing prism shape as the number of turns of the coil for electrical equipment to be manufactured are sliced into thicknesses with equal coil conductor cross-sectional areas. Cut out multiple 1-turn rectangular coils,
The joining process
A plurality of one-turn rectangular coils cut from different block-shaped materials are stacked in an external visual truncated pyramid shape by sequentially shifting the positions of the cutout portions, and the ends and starting ends of adjacent one-turn rectangular coils are overlapped. The method for manufacturing a coil for an electric device according to claim 1, wherein welding or brazing is performed together. The 1-turn coil cutting process
Appearance Cylindrical block material is sliced into equal thicknesses to cut out multiple 1-turn circular coils.
The joining process
A plurality of cut one-turn circular coils are stacked while the positions of the respective cutout portions are sequentially shifted, and the ends and the start ends of adjacent one-turn circular coils are overlapped and welded or brazed. The manufacturing method of the coil for electrical devices of Claim 1. The 1-turn coil cutting process
A block of block-shaped material with the same number of external diameters and the same number of turns as the number of turns of the coil for electrical equipment to be manufactured is sliced to a thickness equal to the coil conductor cross-sectional area, and a plurality of turns Cut out the circular coil,
The joining process
A plurality of one-turn circular coils cut out from different block-shaped materials are stacked in a circular truncated conical shape by sequentially shifting the positions of the notches, and the end and start ends of adjacent one-turn circular coils are overlapped. The method for manufacturing a coil for an electric device according to claim 1, wherein welding or brazing is performed together. The 1-turn coil cutting process
A block-shaped material having a circular truncated conical shape is sliced into thicknesses having equal coil conductor cross-sectional areas, and a plurality of one-turn circular coils are cut out.
The joining process
A plurality of cut 1-turn circular coils are stacked in a truncated cone shape by sequentially shifting the positions of the cutout portions, and the ends and the start ends of adjacent 1-turn circular coils are overlapped for welding or soldering. The manufacturing method of the coil for electric equipment of Claim 1 characterized by the above-mentioned. In a method for manufacturing a coil for an electric device, in which a conductor having a rectangular cross section is wound with its short cross section as a coil axis direction and is laminated spirally in the coil axis direction,
In the block-shaped material having a through hole formed along the material central axis, an opening serving as a notch for dividing the start end and the terminal end of the one-turn coil is communicated with the through hole along the material central axis. A plurality of openings forming step;
A first roller and a second roller, each having a plurality of circumferential grooves formed on the outer circumferential surface, and a wire wound between the circumferential grooves of the first roller and the second roller, A wire saw formed by a plurality of wire portions arranged in parallel with the second roller, and using a wire saw device that linearly moves the wire row together with the rotation of the first roller and the second roller, The wire row of the wire saw device that moves linearly and the block-shaped material formed with the plurality of openings are relatively moved in a state where the linear motion direction of the wire row and the material central axis are substantially orthogonal to each other. The block-shaped material is pressed against the wire row and sliced between adjacent openings of the block-shaped material in the presence of abrasive grains to have the notch for dividing the start end and the end. 1 and turn coil cutout step of cutting a plurality of one-turn coil,
A joining step of joining the plurality of one-turn coils in a spiral manner by laminating the positions of the respective cutout portions sequentially and laminating the ends and the start ends of the adjacent one-turn coils and welding or brazing them. A method for manufacturing a coil for an electric device, comprising: The opening forming step
Each of the plurality of openings is sequentially shifted to the block-shaped material having an external visual prism shape so that the end and start ends of adjacent one-turn coils cut out in the one-turn coil cutting step can be overlapped with each other. Formed,
The 1-turn coil cutting process
Slicing between adjacent openings of the block-shaped material, and cutting out a plurality of 1-turn rectangular coils of equal thickness,
The joining process
8. The adjacent one-turn square coils cut out in the one-turn coil cut-out step are sequentially stacked, and the adjacent end and start ends of adjacent one-turn square coils are welded or brazed. The manufacturing method of the coil for electrical devices of description. The opening forming step
The external dimensions of the block-shaped material are small so that the cross-sectional area of each one-turn coil cut out in the one-turn coil cutting step is equal to the block-shaped material having an external visual frustum shape. The size in the direction of the material central axis is increased, and the end and the start of adjacent one-turn coils are sequentially shifted so as to be superposed on each other,
The 1-turn coil cutting process
Slicing between adjacent openings of the block-shaped material, and cutting out a plurality of 1-turn rectangular coils each having the same conductor cross-sectional area and increasing in thickness as the outer dimension decreases,
The joining process
8. The adjacent one-turn square coils cut out in the one-turn coil cut-out step are sequentially stacked, and the adjacent end and start ends of adjacent one-turn square coils are welded or brazed. The manufacturing method of the coil for electrical devices of description.

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