JP2006318961A - Coil for electric equipment and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil for electronic equipment comprising high-quality edgewise winding having a narrow coil interval, and to provide a method for manufacturing the coil simply and inexpensively with improved productivity. <P>SOLUTION: In the coil 1 for electric equipment, a rectangular conductor is wound with the short side of the section as the direction of a coil axis for spiral lamination. In the coil 1 for electric equipment, successive 1-turn coils 2-1 to 2-15 comprising the conductor having the rectangular section are wound, and a beginning end is butted against a terminal one for welding for spiral lamination. In this case, a welding section 8 is provided between coils where the beginning and terminal ends of the successive 1-turn coils 2-1 to 2-15 are butted in the shape of a sectional area that is larger than the minimum sectional area of the 1-turn coils 2-1 to 2-15 for welding. A sufficient welding area can be ensured, and the coil for electric equipment of the high-quality edgewise winding can be obtained. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to 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, and a manufacturing method thereof.

  Conventionally, as a coil for an electric device, for example, a motor, a so-called flat wipe in which a stator core is formed by winding a round wire in a multi-layer winding, or a flat conductor is wound around a stator core in a multi-layer winding with the long side of a rectangular cross section as a coil axial direction. A so-called edge-wise rectangular coil is known, in which a winding coil or 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 is spirally laminated.

  However, in the case of a coil composed of a multi-layer winding of round wires, for example, a coil occupancy ratio in a slot through which a winding is passed is reduced by forming a gap between the winding start portion in each layer, the vicinity of the top of the core and between layers, The heat radiation of the coil is cut off by the gap, and the motor efficiency is lowered. In addition, when a round wire with a large wire diameter is used, the winding work around the core becomes difficult, and the gap becomes larger, resulting in a significant decrease in coil occupancy and motor efficiency, making the motor smaller and lighter. It becomes difficult.

  In addition, in the case of a flat-wise-wound coil, a void portion is similarly formed in the winding start portion of each layer, the vicinity of the top of the core, and the like, and the coil occupancy rate is reduced. Furthermore, since an insulating layer that insulates between the flat conductors is provided in the radial direction of the coil, the heat dissipation is further deteriorated in combination with the presence of the gap, and the motor efficiency is further reduced.

  On the other hand, since the edge coiled rectangular coil can increase the coil occupying ratio in the slot, there is an advantage that the motor efficiency can be improved and the motor can be reduced in size and weight.

  Conventionally, as a method for manufacturing such a rectangular coil, for example, as shown in FIG. 4, a rotating flaky cutting tool 52 is rotated with respect to a hollow block-shaped material 51 made of extruded copper or aluminum. Is sent in the direction of the arrow to cut a linear groove 53A in the block-shaped material 51, and this groove 53A is processed at an equal pitch to obtain the required number of turns, and then, as shown in FIG. By changing the relative position of the shaped material 51 and the cutting tool 52, the linear groove 53B is formed so that the processing start point and end point are obliquely coupled to the previously processed groove 53A. A method of manufacturing a rectangular coil is known (see, for example, Patent Document 1).

  Further, as another method for manufacturing a rectangular coil, for example, as shown in FIG. 6, one end of each of the two plate pieces 61 </ b> A and 61 </ b> B punched out from a copper plate into a L shape is welded to each other as a welded portion 62. A one-turn coil 61 is formed, and the other end of either one of the plate pieces 61A and 61B is used as a terminal 63 of the one-turn coil 61 and welded to a start end 64 of the next one-turn coil 61 formed in the same manner. A method of manufacturing a square coil having the number of turns is known (see, for example, Patent Document 2).

  Furthermore, this Patent Document 2 forms a square one-turn coil by punching a U-shaped plate piece from a copper plate and welding one end of the U-shaped plate piece and a strip-shaped punched piece. A square piece is punched out of a copper plate and a cut part is formed in a part thereof to form a square one-turn coil, or rectangular copper is cut to form four strip-shaped coil pieces. Also disclosed is a method of manufacturing a square coil with a desired number of turns by welding four coil pieces at three locations to form a square one-turn coil and sequentially welding the similarly formed one-turn coil. Has been.

JP-A-7-163100 JP 2001-178052 A

  However, in the manufacturing method disclosed in Patent Document 1, when the linear groove 53B is cut, the starting point and the end point of the processing are obliquely connected to the previously processed groove 53A. Therefore, high machining accuracy is required.

  For this reason, there is a concern that the productivity is poor and the cost is increased, and the processing start point and end point of the groove 53B are not obliquely connected to the groove 53A and are not accurately connected, 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 53A and 53B are processed by the cutting tool 52, the processing load is large, and the block-shaped material 51 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, there is a concern that the number of turns that can be formed is reduced and the desired performance as a coil cannot be exhibited.

  On the other hand, in the manufacturing method disclosed in the above-mentioned Patent Document 2, a copper plate is punched into a predetermined shape to form a plate piece, or a rectangular piece is cut to form a coil piece, and these are appropriately welded. Therefore, there is an advantage that the square coil can be easily manufactured.

  However, in such a manufacturing method, since the end surface to be welded is cut at right angles to the longitudinal direction of the coil piece, the cross-sectional area of the end surface becomes the minimum cross-sectional area of the coil piece. For this reason, there is a concern that the effective weld length is short, sufficient welding strength cannot be obtained, and the quality of the coil is deteriorated.

  In addition, when the punched plate pieces or the cut coil pieces are overlapped and welded, a space for overlapping is required, and accordingly, the coil interval is widened and the coil occupancy rate is reduced. There is a concern that misalignment is likely to occur during superimposition, thereby changing the heat capacity of welding and causing variations in welding, which also causes a reduction in coil quality.

  The above is not limited to the case of manufacturing a square coil for a motor, but a case of manufacturing a coil of another shape such as edge-wise winding or a coil used for other electrical equipment such as a transformer by the same manufacturing method. Also occurs.

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

  The invention of the coil for electrical equipment according to claim 1, which achieves the above object, winds a sequential one-turn coil made of a conductor having a rectangular cross section with the short side of the cross section as the coil axis direction, and abuts the start and end In the coil for electrical equipment, which is welded and laminated in a spiral shape, the coil-to-coil welding in which the start end and the end of the sequential one-turn coil are butted in a cross-sectional shape larger than the minimum cross-sectional area of the coil. It has the part.

  According to a second aspect of the present invention, in the coil for an electric device according to the first aspect, the one-turn coil is a square coil, and a corner portion of the square coil includes the inter-coil weld portion.

  According to a third aspect of the present invention, in the coil for an electric device according to the second aspect, each of the rectangular coils is a trapezoidal coil having a strip shape when viewed in the axial direction of the coil and having both end faces inclined with respect to the longitudinal direction. It has the welding part in a coil which faced and welded the said end surfaces of a piece, It is characterized by the above-mentioned.

  Furthermore, the invention for manufacturing a coil for an electric device according to claim 4 which achieves the above object is characterized in that a sequential one-turn coil made of a conductor having a rectangular cross section is wound with the short side of the cross section as the coil axis direction and a starting end. A plurality of trapezoidal shapes in which both ends are inclined with respect to the longitudinal direction when viewed in the axial direction of the coil. And a step of abutting and welding the end faces of the plurality of coil pieces.

  According to a fifth aspect of the present invention, in the coil manufacturing method for an electric device according to the fourth aspect, the plurality of trapezoidal coil pieces are formed by pressing a conductive flat plate.

  According to a sixth aspect of the present invention, in the method of manufacturing a coil for an electric device according to the fourth aspect, the plurality of trapezoidal coil pieces are formed by cutting a rectangular wire obliquely with respect to its longitudinal direction. Features.

  According to the first aspect of the present invention, in the inter-coil weld portion for welding the start and end of the sequential one-turn coil, the shape of the cross-sectional area where the start and end of the sequential one-turn coil is larger than the minimum cross-sectional area of the coil. Since the welding is performed in a manner such that the coil interval can be reduced, a sufficient welding area can be secured, and a high-quality edge-wise coil for electrical equipment can be obtained.

  According to the second aspect of the present invention, the one-turn coil is a square coil, and the corner portion is welded between the start and end of the sequential one-turn coil using the inter-coil welded portion. In this case, the coil occupation ratio can be effectively increased.

  According to the invention of claim 3, since the one-turn rectangular coils are each formed in a strip shape and both end faces are inclined with respect to the longitudinal direction, the end faces of the trapezoidal coil pieces are butted together in the in-coil weld, The coil occupancy is not reduced, and a sufficient welding area can be secured at each welded portion in each coil, so that a high-quality edgewise-wound rectangular coil can be obtained.

  According to the invention of claim 4, since a plurality of trapezoidal coil pieces are formed in a strip shape whose both end faces are inclined with respect to the longitudinal direction, the end faces of these coil pieces are butted together and welded. The welding surface can be easily and accurately aligned. Therefore, it is possible to easily and inexpensively manufacture a coil for an electric device composed of a square coil with a high coil occupation ratio and a high quality edgewise winding.

  According to the invention of claim 5, since a plurality of trapezoidal coil pieces are formed by pressing a conductive flat plate, the coil pieces can be formed easily and efficiently. As a result, the productivity and low cost of the coil for electrical equipment are achieved. Further improvement can be expected.

  According to the invention of claim 6, since the plurality of trapezoidal coil pieces are formed by cutting a rectangular wire, the coil pieces can be formed easily and efficiently as in the case of claim 5, and as a result, the electric equipment Further improvement in coil productivity and cost reduction can be expected.

  Hereinafter, an embodiment of a coil for electric equipment and a method for manufacturing the same according to the present invention will be described with reference to FIGS.

  FIG. 1 is a perspective view of a coil for electric equipment according to the present embodiment, and FIG. 2 is a plan view seen from the coil axis direction.

  The coil 1 for an electric device according to the present embodiment is an edgewise-wound rectangular coil that is loaded into a prismatic core having a rectangular cross section, and constitutes a plurality of turns made of a flat conductor, in this embodiment, 15 turns. The one-turn coils 2-1 to 2-15 are stacked in the axial direction of the core, that is, in the coil axial direction A along the outer peripheral surface of the core, and are spirally connected. Each one-turn coil 2-1 to 2-15 is made of a conductive material such as copper or aluminum, and has a substantially rectangular through-hole through which a prismatic core with a rectangular cross section (not shown) passes, The outer shape orthogonal to the axial direction A is a square, and is formed in an annular shape that is continuous in a rectangular cross section having a width dimension larger than a thickness direction dimension. In FIG. 2, 1-turn coils 2-1 to 2-4 for four turns are shown for the sake of clarity.

  Each of the 1-turn coils 2-1 to 2-15 has the same cross-sectional area, and in the thickness direction in order from the stacked 1-turn coil 2-1 side to the 1-turn coil 2-15 side. The dimensions in the width direction are gradually reduced, while the dimensions in the width direction are sequentially increased to form the electric device coil 1 having an external view trapezoidal shape.

  Further, each one-turn coil 2-1 to 2-15 has four trapezoidal coil pieces 3 to 6 which are strip-shaped when viewed from the coil axis direction A and whose both end surfaces are inclined with respect to the longitudinal direction. And one end surface 3-1 of the coil piece 4, one end surface 4-1 of the coil piece 4, the other end surface 4-2 of the coil piece 4, one end surface 5-1 of the coil piece 5, and the coil piece 5 The other end face 5-1 and one end face 6-1 of the coil piece 6 are each butted and welded by, for example, an electron beam, as shown in a partially enlarged view in FIG. Three in-coil welds 7-1 to 7-3 connecting 3 to 6 are formed at the corners.

  Further, each one-turn coil 2-1 to 2-15 has the other end face of the coil piece that is the terminal end of the previous one-turn coil, with the other end face 3-2 of the coil piece 3 serving as, for example, the start end of the one-turn coil. The inter-coil welded portion 8 is formed so as to connect the start end and the end of the sequential one-turn coils 2-1 to 2-15.

  For example, the other end face 3-2a of the coil piece 3-1 constituting the one-turn coil 2-1 serving as the starting end of the coil 1 for electric equipment and the one-turn coil 2-15 serving as the terminal end of the coil 1 for electric equipment. The other end face of the coil piece 6-1 constituting the coil piece is not necessarily welded to each other, and therefore it is not always necessary to form the end face inclined with respect to the longitudinal direction of the coil piece. For example, as shown in FIGS. Further, it may be formed at right angles to the longitudinal direction of the coil piece.

  In the present embodiment, the above-described electric device coil 1 is manufactured as follows. First, a strip for forming one-turn coils 2-1 to 2-15 by pressing a conductive flat plate such as copper or aluminum or cutting a rectangular wire obliquely with respect to its longitudinal direction. The trapezoidal coil pieces 3 to 6 whose both end faces are inclined with respect to the longitudinal direction are formed.

  Next, the end faces of the coil pieces 3 to 6 are butted together and sequentially welded by an electron beam to form the 1-turn coils 2-1 to 2-15, respectively, and then the sequential 1-turn coils 2-1 to 2- Similarly, the end faces of the trapezoidal coil pieces 3 to 6 serving as the terminal end and the starting end of 15 are sequentially welded with an electron beam to produce the coil 1 for electric equipment.

  Alternatively, the end faces of the coil pieces 3 to 6 are sequentially butt-welded without forming the one-turn coils 2-1 to 2-15, thereby connecting the one-turn coils 2-1 to 2-15 as a result. Thus, the coil 1 for electric equipment is manufactured.

  As described above, in the present embodiment, a plurality of trapezoidal coil pieces 3 to 6 are formed in a strip shape by pressing a conductive flat plate or cutting a flat wire and both end faces are inclined with respect to the longitudinal direction. Since the coil 1 for electrical equipment is manufactured by butt-welding the end faces of the coil pieces 3 to 6 to form the coil piece 3 to 6, the coil pieces 3 to 6 can be easily and efficiently formed. The coil 1 for electric equipment which consists of can be manufactured easily and cheaply with sufficient productivity. And the end surface which inclines with respect to the longitudinal direction of the coil pieces 3-6 is butt-welded, and the space | interval of each 1-turn coils 2-1 to 2-15 can be narrowed.

  Further, end faces where the in-coil welds 7-1 to 7-3 for forming the respective one-turn coils 2-1 to 2-15 are inclined with respect to the longitudinal direction of the respective one-turn coils 2-1 to 2-15. That is, since the cross-sectional area larger than the minimum cross-sectional area of each one-turn coil 2-1 to 2-15 orthogonal to the longitudinal direction of each one-turn coil 2-1 to 2-15 is butt-welded. A sufficient welding area of the in-coil welds 7-1 to 7-3 can be secured. In addition, the inter-coil welds 8 that connect the 1-turn coils 2-1 to 2-15 are butted at the end surfaces that are inclined with respect to the longitudinal direction of the 1-turn coils 2-1 to 2-15. And butt welded in a shape of a cross-sectional area larger than the minimum cross-sectional area of each one-turn coil 2-1 to 2-15 orthogonal to the longitudinal direction of each one-turn coil 2-1 to 2-15, A sufficient welding area can be secured. Further, since the positions of the welded surfaces 7-1 to 7-3 and 8 can be easily and accurately aligned, the coil occupancy can be increased and the coil quality can be improved. In particular, if electron beam welding is adopted as butt welding, the generation of voids during recrystallization of the coil material during welding can be prevented, and at the same time, the structure can be prevented from being oxidized. it can.

  Note that the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the invention. For example, each one-turn coil is not limited to the case where it is formed of four strips and trapezoidal coil pieces 3 to 6 whose both end faces are inclined with respect to the longitudinal direction. For example, as shown in FIG. Both end faces 13 of the two L-shaped coil pieces 11 and 12 are formed so as to be inclined and butt-welded in the same manner, or as shown in FIG. A one-turn coil 15 is formed by dividing at the end face 14, and butt welding is performed on the end faces 14 of the sequential one-turn coils 15. Alternatively, as shown in FIG. The one-turn coil 17 can be formed by being divided by the end face 16 inclined at the center portion, and the successive one-turn coils 17 can be similarly butt welded to the end face 16. In addition, the present invention is not limited to a trapezoidal electric device coil in appearance, and can also be applied to edge-winding electric device coils having various coil shapes such as a rectangular coil and a cylindrical coil. It is.

It is a perspective view of the coil for electric equipment concerning an embodiment of the invention. It is the figure which looked at the coil for electric devices shown in FIG. 1 from the coil axial direction. It is a figure for demonstrating the modification of the coil for electric devices which concerns on this invention. It is explanatory drawing of the conventional coil manufacturing method. Similarly, it is explanatory drawing of a coil manufacturing method. It is explanatory drawing of the other conventional coil manufacturing method.

Explanation of symbols

1 Coil for electrical equipment 2-1 to 2-15 1 turn coil 3 to 6 Coil piece 3-1, 3-2, 4-1, 4-2, 5-1, 5-2, 6-1, 6 2 End surface 7-1 to 7-3 Welded part in coil 8 Welded part between coils A Coil axial direction

Claims (6)

In a coil for electrical equipment, in which a sequential one-turn coil made of a conductor having a rectangular cross section is wound with the short side of the cross section as the coil axis direction and welded with the start end and the end faced but welded,
A coil for electric equipment, comprising an inter-coil weld portion in which a start end and a terminal end of the sequential one-turn coil are welded with a cross-sectional area larger than the minimum cross-sectional area of the coil being welded.   The coil for electrical equipment according to claim 1, wherein the one-turn coil is formed of a square coil, and has a weld portion between the coils at a corner portion of the square coil.   Each of the rectangular coils has a welded part in a coil which is a strip shape in a state viewed from the coil axial direction and welded by abutting the end faces of the trapezoidal coil pieces whose both end faces are inclined with respect to the longitudinal direction. The coil for electrical equipment according to claim 2. A method of manufacturing a coil for an electric device in which a sequential one-turn coil made of a conductor having a rectangular cross section is wound with the short side of the cross section as a coil axial direction and welded with the start end and the end abutted against each other. In
A step of forming a plurality of trapezoidal coil pieces that are strip-shaped and both end faces are inclined with respect to the longitudinal direction in the coil axis direction view state;
A process of abutting and welding the end faces of the plurality of coil pieces;
A method for manufacturing a coil for electrical equipment, comprising:   The method for manufacturing a coil for an electric device according to claim 4, wherein the plurality of trapezoidal coil pieces are formed by pressing a conductive flat plate. 5. The method of manufacturing a coil for an electric device according to claim 4, wherein the plurality of trapezoidal coil pieces are formed by cutting a rectangular wire obliquely with respect to a longitudinal direction thereof.

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