JP2005204422A - Method of manufacturing coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve a space factor by avoiding damage to an insulating cover. <P>SOLUTION: This method of manufacturing a coil includes a step (S1000) of winding an element wire a plurality of times around bobbins the interval between which can be adjusted freely, a step (S1100) of forming the wound element wire roughly into the shape of a coil by widening the interval, steps(S1200 and S1300) of forming it into the shape of a coil by giving an external force from the outside of the wound element wire to its inside and the external force to stick the fellow turns of the wound element wire fast to one another while keeping the interval between the bobbins, a step(S1400) of applying insulation treatment a part between turns of the wound element wire, and a step (S1500) of supplying the wound element wire with power. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a stator including a stator core and a coil, and more particularly to a method for manufacturing a coil.

  Conventionally, a coil is formed by winding a conductor wire while applying tension to a winding frame of a predetermined shape. The coil wire is provided with an insulation coating such as enamel. For this reason, when winding while applying tension to the strands, the coil wires come into contact with each other, so that there is a possibility that the insulating coating may be scratched or peeled off.

  Therefore, in view of such problems, Patent Document 1 (Japanese Patent Laid-Open No. 2000-197294) discloses a concentrated winding coil and a winding manufacturing apparatus that prevent damage to the enamel coating of the coil using a rectangular wire. The concentrated winding coil is wound so that a coil wire having a rectangular shape forms a plurality of layers. In a concentrated winding coil in which coil wires are wound to form a row in each layer, the cross-sectional shape of the coil wire is round at the turnover portion where the coil wire moves to the next row and at the turnover portion where the coil wire moves to the next layer. It is a shape.

According to the concentrated winding coil disclosed in Patent Document 1, the coil wire partially has a round cross section at the replacement part and the layer change part. When the coil wires cross each other, the edges of the flat portions do not contact each other, but the round wire portions contact each other, so that the contact stress is remarkably relieved and damage to the coil wire coating can be prevented. In particular, damage to the coating can be effectively prevented when the wound coil is formed into an arc shape as a whole.
JP 2000-197294 A

  However, when forming a coil with a high space factor (ratio of the cross-sectional area of the coil to the cross-sectional area of the slot provided in the stator core) and winding the wire while applying tension to the winding frame, The insulation coating is damaged by the contact between them. Further, since the wire is formed while tension is applied, the wire is extended and it is difficult to manage the resistance value. Therefore, there has been a problem that it is difficult to manage the quality of the coil.

  In addition, in the concentrated winding coil disclosed in Patent Document 1, when forming a coil using a strand such as a flat wire, the insulation coating is peeled off when the insulation-coated strand is deformed until it is plastically deformed. There was a problem. That is, it is difficult to make the coil the same shape as the cross-sectional shape of the slot in order to increase the space factor. For this reason, there is a limit to improving the space factor.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a method of manufacturing a coil that improves the space factor by avoiding damage to the insulating coating.

  A method for manufacturing a coil according to a first aspect of the present invention is a method for manufacturing a coil constituting a stator of a rotating electrical machine including a stator and a rotor. The coil manufacturing method includes a winding step of winding a wire forming the coil a plurality of times, a step of forming the coil into a predetermined shape, and an insulation treatment between the wires in the wound wire And a step of supplying power to the wound wire.

  According to the first invention, the insulation treatment is performed between the strands of the strand wound in the processing step. Power is supplied to the wound wire in the step of supplying power. Thereby, the coil can be contracted. That is, by supplying power to the wound wire, a magnetic field is generated in the coil formed by the wire. At this time, based on the magnetic field generated in the coil, a so-called energization contraction occurs in which a force is generated and contracts in a direction in which the strands are in close contact with each other. The coil can be shrunk without contact from the outside, and the density of the coil is improved, so that the insulation of the cross section of the coil wound around the teeth is improved and the space factor between the teeth is improved. The manufacturing method of the coil to be made can be provided.

  In the method for manufacturing a coil according to the second invention, in addition to the configuration of the first invention, the winding step includes a step of winding the element wire around a member whose space can be freely adjusted. The step of forming in a predetermined shape is a first forming step in which the wound wire is formed so as to have a schematic shape of the coil by widening the interval, and maintaining the interval between the members, A second forming step in which an external force from the outside to the inside of the wound strands and an external force for bringing the wound strands into close contact with each other are applied to form a coil shape.

  According to the second invention, in the coil manufacturing method, in the step of winding the wire a plurality of times, the wire forming the coil on a member (for example, two winding frames) whose space can be freely adjusted. Is wound several times. Then, in the first forming step, an external force from the inside to the outside is applied to the wound wire by widening the interval between the two winding frames. The wound wire is formed so as to have a general shape of a coil. Then, in the second forming step, an external force from the outside to the inside and an external force for bringing the wound strands into close contact with each other are applied to the wound strands to form a coil shape. To do. And in a process step, an insulation process is performed between the strands in the wound strand. A predetermined coil shape can be obtained by applying an external force from the inside to the outside, an external force from the outside to the inside, and an external force for bringing the wound strands into close contact with each other after winding the wire on the winding frame. . At this time, since the insulation treatment is performed after the coil shape is formed, the problem that the insulation coating or the like is peeled off can be avoided even if an external force that causes plastic deformation is applied to the element wire. In addition, it is possible to form a coil shape with higher accuracy than in the case where the coil is formed only by an external force from the outside to the inside. Further, this coil is formed into a coil shape and then covered with insulation. And it is assembled | attached to the teeth of a stator core in the state by which insulation coating was carried out. Therefore, the cross-sectional shape of the coil in the slot provided between the teeth can be formed with high accuracy. That is, the cross-sectional shape of the coil can be made a shape with improved space factor, which is the ratio of the cross-sectional area of the coil to the cross-sectional area of the slot. Copper loss can be reduced by improving the space factor. Therefore, damage to the insulating coating can be avoided and the space factor can be improved. In addition, since it is not necessary to wind the wire around the stator core while constantly applying tension, it is possible to prevent the wire from extending due to the tension. That is, since the resistance value of the strand does not change, the coil quality can be easily managed.

  In the coil manufacturing method according to the third invention, in addition to the configuration of the first or second invention, the processing step includes a step of attaching an inorganic insulating material to the wound wire.

  According to the third invention, the inorganic insulating material is attached to the wound wire in the processing step. The insulation process is performed after the coil shape is formed. For this reason, an inorganic insulating material having higher heat resistance and withstand voltage than that of an organic insulating coating such as flexible enamel, which has been used as an insulating material for coils in the past, is attached to the wound wire for insulation. Processing can be performed. Therefore, an insulating coating having high heat resistance and high withstand voltage can be applied to the coil.

  In the coil manufacturing method according to the fourth aspect of the invention, in addition to the structure of any one of the first to third aspects, the iron core of the stator is provided with a tooth around which the coil is wound and a slot between the teeth. . The shape of the coil is such that the cross-sectional shape of the coil can be stored in a predetermined range in the slot.

  According to the fourth invention, a slot is provided between the teeth around which the coil is wound on the iron core of the stator. The shape of the coil is formed such that the cross-sectional shape of the coil is in a predetermined range in the slot (for example, a range in which the coil can be stored). By making the cross-sectional shape of the coil into a shape in which the coil of the slot can be accommodated, the space factor of the coil with respect to the slot can be improved.

  In the coil manufacturing method according to the fifth invention, in addition to the configuration of any one of the first to fourth inventions, the cross-sectional shape of the element wire is a quadrangular shape.

  According to 5th invention, the clearance gap between strands can be reduced by making the cross-sectional shape of a strand into a square shape. Therefore, the density of the coils can be improved. As a result, the cross-sectional shape of the coil wound around the teeth can be made a shape with a higher space factor in the slots between the teeth.

  In the coil manufacturing method according to the sixth invention, in addition to the configuration of any one of the first to fourth inventions, the cross-sectional shape of the wire in the coil formed in the second forming step is a hexagonal shape. .

  According to the sixth invention, when the coil shape is formed, the cross-sectional shape of the wire has a hexagonal shape. For example, a strand having a round cross section is wound around a member (for example, a winding frame) whose spacing can be freely adjusted a plurality of times. Then, an external force from the inside to the outside and an external force in a direction in which the inside and the wires are brought into close contact with each other are respectively applied to the wound strands, and pressed to such an extent that they are plastically deformed. As a result, the round cross section of the strands is deformed so that the gap between the strands is reduced. The round cross section is transformed into a hexagonal cross section. Therefore, since the gap between the strands is reduced by forming the coil with strands having a hexagonal cross section, the density of the coils can be improved. As a result, the cross-sectional shape of the coil wound around the teeth can be made a shape with a higher space factor in the slots between the teeth.

  Hereinafter, a method for manufacturing a coil according to an embodiment of the present invention will be described with reference to the drawings. In the following description, the same parts are denoted by the same reference numerals. Their names and functions are also the same. Therefore, detailed description thereof will not be repeated.

<First Embodiment>
The rotating electrical machine includes a stator and a rotor. And a stator is comprised from a stator iron core and a coil. The stator core according to the present embodiment has a hollow cylindrical shape. The stator iron core is provided with a plurality of tooth-shaped teeth on the inner peripheral side. The coil is wound around this tooth. A stator is formed by connecting coils wound around a plurality of teeth, respectively.

  As shown in FIG. 1, the coil 118 manufactured by the manufacturing method according to the embodiment of the present invention is formed by winding a conductor wire 100 having a quadrangular cross section a plurality of times. The coil 118 is wound around the teeth 102 provided on the stator core 104. At this time, the coil 118 is assembled to the tooth 102 in a state of being formed in a coil shape in advance.

  Below, the manufacturing method of the coil 118 which concerns on this Embodiment is demonstrated in detail using the flowchart of FIG.

  That is, in step (hereinafter, step is abbreviated as S) 1000, the wire 100 is wound around the winding frame 106 and the winding frame 108. As shown in FIG. 3, the strand 100 is wound around the winding frame 106 and the winding frame 108 a plurality of times. The winding frame 106 and the winding frame 108 are two members that can freely adjust the distance from each other. In the present embodiment, two members are used as the winding frame, but are not particularly limited. For example, the winding frame may be composed of a plurality of members.

  The strand 100 is wound around the winding frame 106 and the winding frame 108 while applying a weak tension that does not cause plastic deformation of the strand 100.

  In S1100, as shown in FIG. 4, the interval between the reel 106 and the reel 108 is increased. By expanding the space between the winding frame 106 and the winding frame 108, an external force from the inside to the outside is applied to the wound wire 100. As a result of the external force being applied, the wound wire 100 has a general shape of a coil. At this time, the interval between the expanded winding frames is an interval designed so that a predetermined gap is generated between the width of the two expanded winding frames and the width of the teeth of the stator core. In other words, the interval is such that the coil 118 can be assembled to the teeth of the stator core.

  In S1200, an external force from the outside to the inside is applied to the wound strand 100. As shown in FIG. 5, in a state where the interval between the winding frame 106 and the winding frame 108 is widened, that is, in a state where an external force is applied from the inside to the outside with respect to the wound wire 100, An external force is applied to the wound wire 100 using 112, 114, and 116. Specifically, the pressing members 110 and 116 are used to apply an external force in a direction in which the strands are in close contact with each other so as to sandwich the wound strand 100. Further, the pressure members 112 and 114 are used to apply an external force from the outside to the inside of the wound strand 100 so as to sandwich the wound strand 100. At this time, the external force applied to the wound wire 100 is an external force that causes plastic deformation.

  In S1300, external force is applied to the wound strand 100 in the direction in which the strands are in close contact with each other. By applying the external force as described above to the wound wire 100, the wire 100 forms the shape of the coil 118 as shown in FIG. At this time, it is possible to form a desired coil shape by changing the interval of expanding the winding frame and the shape of the pressure members 110, 112, 114, 116. Further, the order of S1200 and S1300 is not particularly limited.

  In S1400, the strands 100 forming the coil 118 are insulated. That is, as shown in FIG. 7, the coil 118 is impregnated with an insulating material, and the insulating material is attached to the wound wire 100. At this time, the insulating material is not particularly limited. For example, an organic insulating material such as enamel may be used, or an inorganic insulating material such as ceramics or glass fiber may be used. Further, the insulation treatment is not particularly limited to impregnation. For example, it may be molded or impregnated in a vacuum atmosphere.

  In S1500, electric power is supplied to the coil 118 that has been subjected to insulation treatment, as shown in FIG. A magnetic field is generated in the coil 118 in response to the supply of electric power. Based on the generated magnetic field, a force acts in a direction in which the strands of the coil 118 are in close contact with each other. Thus, the coil 118 is so-called energized and contracted. By this energization contraction, the gap between the strands is reduced and the density of the coils 118 is improved. Further, when the manufacturing method described above is used, it is possible to form a desired coil shape by changing the interval of expanding the winding frame and the shape of the pressure members 110, 112, 114, and 116. That is, for example, the cross-sectional shape of the coil can be a shape that can be accommodated in a predetermined range in the slot. The teeth around which the coil is wound are provided with two slots. In this slot, a coil wound around adjacent teeth coexists. For this reason, the range in which the coil can be stored is set to a range as shown in FIG. Therefore, the space factor of the coil with respect to the slot can be improved by setting the cross-sectional shape in the slot of the coil 118 to a shape that can accommodate the coil as shown in FIG. Specifically, as shown in FIG. 9B, the wire is wound around the winding frames 126 and 124. And the space | interval of the winding frames 124 and 126 is expanded only the space | interval corresponding to the dimension of the width | variety of teeth. In this way, an external force from the inside to the outside is applied to the wound wire. And in the state which expanded the space | interval, the external force from the outer side to the inner side is provided so that the strand wound using the pressurization members 120 and 130 may be inserted | pinched. And the external force of the direction parallel to the longitudinal direction of the winding frames 124 and 126 is given using the pressurizing members 122 and 128, ie, the direction in which strands contact | adhere. The coil 132 is formed by applying the external force as described above. The density of the coil 132 is improved by energizing and contracting the coil 132. The coil 132 formed in this way is assembled to the tooth 102 as shown in FIG. Thus, the space factor of the coil with respect to a slot can be improved by making the cross-sectional shape of the coil in a slot into the shape of the range which can be accommodated in a slot.

  As described above, according to the method for manufacturing a coil according to the present embodiment, an insulation process is performed between the strands of the strand wound in the processing step. Power is supplied to the wound wire in the step of supplying power. Thereby, the coil can be contracted. That is, by supplying power to the wound wire, a magnetic field is generated in the coil formed by the wire. At this time, based on the magnetic field generated in the coil, a so-called energization contraction occurs in which a force is generated and contracts in a direction in which the strands are in close contact with each other. The coil can be shrunk without contact from the outside, and the density of the coil is improved, so that the insulation of the cross section of the coil wound around the teeth is improved and the space factor between the teeth is improved. The manufacturing method of the coil to be made can be provided.

  Further, in the step of winding the strands a plurality of times, the strands forming the coil are wound a plurality of times on two winding frames whose spacing can be freely adjusted. Then, in the step of forming the first coil, an external force from the inside to the outside is applied to the wound wire by widening the interval between the two winding frames. The wound wire is formed so as to have a general shape of a coil. Then, in the formation step of the second coil, an external force from the outside to the inside of the wound strands and an external force for bringing the wound strands into close contact with each other are formed to form a coil shape. To do. And in a process step, an insulation process is performed between the strands in the wound strand. A predetermined coil shape can be obtained by applying an external force from the inside to the outside, an external force from the outside to the inside, and an external force for bringing the wound strands into close contact with each other after winding the wire on the winding frame. . At this time, since the insulation treatment is performed after the coil shape is formed, the problem that the insulation coating or the like is peeled off can be avoided even if an external force that causes plastic deformation is applied to the element wire. In addition, it is possible to form a coil shape with higher accuracy than in the case where the coil is formed only by an external force from the outside to the inside. Further, this coil is formed into a coil shape and then covered with insulation. And it is assembled | attached to the teeth of a stator core in the state by which insulation coating was carried out. Therefore, the cross-sectional shape of the coil in the slot provided between the teeth can be formed with high accuracy. That is, the cross-sectional shape of the coil can be made a shape with improved space factor, which is the ratio of the cross-sectional area of the coil to the cross-sectional area of the slot. Copper loss can be reduced by improving the space factor. Therefore, damage to the insulating coating can be avoided and the space factor can be improved. Further, since it is not necessary to wind the wire around the stator core while applying tension, it is possible to prevent the wire from extending due to the tension. That is, since the resistance value of the strand does not change, the coil quality can be easily managed.

  In the processing step, an inorganic insulating material is attached to the wound wire. The insulation process is performed after the coil shape is formed. For this reason, an inorganic insulating material having higher heat resistance and withstand voltage is attached to the wound wire than the organic insulating coating such as flexible enamel that has been conventionally used as an insulating material for coils. Insulation treatment can be performed. Therefore, an insulating coating having high heat resistance and high withstand voltage can be applied to the coil.

  Further, a slot is provided between the teeth around which the coil is wound on the iron core of the stator. The shape of the coil is formed so that the cross-sectional shape of the coil is in a predetermined range in the slot. The predetermined range is a range in which the coil can be stored. By making the cross-sectional shape of the coil into a shape in which the coil of the slot can be accommodated, the space factor of the coil with respect to the slot can be improved.

<Second Embodiment>
Hereinafter, the manufacturing method of the coil which concerns on 2nd Embodiment is demonstrated. The coil according to the present embodiment is different in the shape of the wire of the coil according to the first embodiment described above.

  As shown in FIG. 10, in the coil 202 according to the present embodiment, the cross-sectional shape of the strand 200 becomes a hexagon when the coil shape is formed. In addition, the cross-sectional shape of the strand 200 when wound on the winding frame may be a hexagonal shape or a round shape.

  When the coil shape is formed using the round wire, the external force from the inside to the outside, the outside to the inside, as in the first embodiment described above, with respect to the wound round wire By applying an external force to the wire and an external force in a direction in which the strands are in close contact with each other, the round cross section is plastically deformed so that a gap between the round strands is reduced. A strand having a round cross section is plastically deformed into a substantially hexagonal cross section.

  When the coil 204 is formed so that the cross-sectional shape of the strand 200 becomes a hexagonal shape or a substantially hexagonal shape when the coil shape is formed in this way, the gap between the strands is reduced. Therefore, the density of the coils 202 can be improved.

  The method for manufacturing the coil according to the present embodiment is the same as the procedure shown in the flowchart of FIG. 2 described in the first embodiment. Therefore, detailed description will not be repeated.

  Here, in the first embodiment described above, the cross-sectional shape of the coil 204 is obtained by using the winding frames 124 and 126 and the pressing members 110, 112, 114, and 116 described with reference to FIG. 9B. As shown in FIG. 11A, it can be formed so as to have a shape that can be stored in the slot. The coil 204 formed in this way is assembled to the tooth 102 as shown in FIG. The space factor of the coil with respect to the slot can be improved by forming the cross-sectional shape of the coil in the slot by applying an external force so that the coil has a shape in a range in which the coil can be accommodated.

  As described above, according to the method for manufacturing a coil according to the present embodiment, by forming the coil so that the cross-sectional shape of the strand becomes a hexagonal shape or a substantially hexagonal shape when the coil shape is formed, The density of the coil can be improved. Moreover, the space factor of a coil can be improved by making the cross-sectional shape of the coil in a slot into the shape of the range which can accommodate a slot. In addition, the cross-sectional shape of the strand is not particularly limited to a quadrangular shape or a hexagonal shape. That is, the cross-sectional shape of the strands may be any shape that reduces the gap between the strands when the coil shape is formed.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is an external view of the coil wound around the stator core according to the first embodiment. It is a flowchart which shows the manufacturing method of the coil which concerns on 1st Embodiment. It is a figure of the coil wound by the winding frame which concerns on 1st Embodiment. It is a figure of the coil to which the external force from the inner side to the outer side which concerns on 1st Embodiment is provided. It is a figure of the coil to which the external force from the outer side to the inner side which concerns on 1st Embodiment is provided. It is a figure of the coil to which the external force of the grade which carries out the plastic deformation which concerns on 1st Embodiment was provided. It is a figure of the coil in which the insulation process which concerns on 1st Embodiment is performed. It is a figure of the coil by which the electric power which concerns on 1st Embodiment is supplied. It is a figure of the coil wound by the range which can be accommodated in the slot which concerns on 1st Embodiment. It is an external view of the coil wound around the stator core which concerns on 2nd Embodiment. It is a figure of the coil wound by the range which can be accommodated in the slot which concerns on 2nd Embodiment.

Explanation of symbols

  100, 200 strand, 102 teeth, 104 stator core, 106, 108, 124, 126 reel, 110, 112, 114, 116, 120, 122, 128, 130 pressure member, 118, 132, 202, 204 coil.

Claims (6)

A method of manufacturing a coil constituting the stator of a rotating electrical machine comprising a stator and a rotor,
A winding step of winding the wire forming the coil a plurality of times;
Forming the coil into a predetermined shape;
A treatment step of performing an insulation treatment between the wires in the wound wire;
Supplying a power to the wound wire. The winding step includes a step of winding the element wire on a member whose space can be freely adjusted.
The step of forming into the predetermined shape includes:
A first forming step of forming the wound wire so as to have a schematic shape of the coil by widening the interval;
Applying an external force from the outside to the inside of the wound strands and an external force for bringing the wound strands into close contact with each other while maintaining the spacing between the members so that the coil is shaped. The manufacturing method of the coil of Claim 1 including the 2nd formation step to form.   The coil manufacturing method according to claim 1, wherein the processing step includes a step of attaching an inorganic insulating material to the wound wire. A tooth around which a coil is wound around the iron core of the stator, and a slot is provided between the teeth,
The method of manufacturing a coil according to any one of claims 1 to 3, wherein the shape of the coil is a shape in which a cross-sectional shape of the coil can be stored in a predetermined range in the slot.   The cross-sectional shape of the said strand is a manufacturing method of the coil in any one of Claims 1-4 which is square shape.   The manufacturing method of the coil in any one of Claims 1-4 whose cross-sectional shape of the strand in the coil formed in a said 2nd formation step is hexagonal shape.

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