JP2007028777A - Laminated electromagnetic coil with different inside diameter shape and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for easily manufacturing an electromagnetic coil with different inside diameter shapes. <P>SOLUTION: In the method for manufacturing the laminated electromagnetic coil, a fusion conductor 1 is adjusted to and wound onto a mount space of the coil and forms a plurality of alpha-wound electromagnetic coils with the different inside diameter shapes, a plurality of the electromagnetic coils with the different number of turns are heated and pressed before or after a lamination and connected in series or parallel, and a portion or all of the inside diameter shape is a truncated cone or a truncated pyramid. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an air-core alpha- wound laminated electromagnetic coil having a different inner diameter shape using a fused conductor and a method for manufacturing an air-core alpha-winded laminated electromagnetic coil.

  Air-core electromagnetic coils having different inner diameter shapes using fused conductors are extremely difficult due to the winding structure of the coils, and cannot be realized due to the disadvantage that alpha winding and alignment winding cannot be performed.

Moreover, it is almost impossible to wind the electromagnetic coils having different inner diameter shapes while securing the space factor of the coil in the air core winding jig shape and the winding work.

The problem to be solved is that, as a manufacturing method of electromagnetic coils having different inner diameter shapes with fused conductors, the conventional air-core winding cannot secure a space factor above a certain level from the coil shape.

In order to solve the above-mentioned problem, the present invention implements a plurality of coils having different inner diameters with an air core as the fusion lead wire and alpha winding, and aligns the plurality of coils having different inner diameters with the coil storage space. By bonding, electromagnetic coils having different inner diameter shapes are provided. In a plurality of coil stacks with different inner diameter shapes, each coil surface has dimensional variations. By heating and pressing the coils, the dimensional variation can be made extremely small, and the smoothness of the stacked surfaces (the unevenness of the coil stacked surfaces) In addition, a plurality of electromagnetic coils having different inner diameter shapes and different numbers of windings can be easily bonded together, and variation in finished dimensions can be extremely reduced. Also, when bending at least one surface in the thickness direction or the direction orthogonal to the thickness direction, bending and laminating can be easily performed by heating and pressing. That is, it is to easily provide electromagnetic coils having different inner diameter shapes.

In addition, a plurality of alpha-wound electromagnetic coils having different inner diameter shapes and different numbers of windings are mounted and fixed on a lamination jig in the lamination process without high-precision processing, and heating means such as resistance, infrared rays, and hot air are provided. Provided is a manufacturing method for laminating electromagnetic coils while removing dimensional accuracy variations of laminated coils by heating and pressing dimensional variations due to winding distortion generated at the time of rising.

In a laminated laminated electromagnetic coil having a truncated pyramid or truncated cone shape, the space factor is greatly influenced by the fusion-conducting wire diameter and the cross-sectional area at a small coil size. In order to further increase the density, it is possible to minimize the dead space in the winding wire by laminating and laminating the alpha winding coil by the above-described method with a combination of the fused conducting wire diameters or conducting wires having different cross-sectional areas. It is possible to provide a high-density laminated electromagnetic coil having different inner diameter shapes.

  The fusion-coiled alpha winding electromagnetic coil of the present invention is wound on a rectangular shape or a circular shape with an arbitrary number of turns using a commonly used fusion wire, and the coil is heated and pressed at the time of winding or after winding to obtain a thickness. Curved at least one of the thickness direction or the direction orthogonal to the thickness direction, and the electromagnetic coil in which a plurality of coils with different number of turns are stacked and connected in series or in parallel. Laminated electromagnetic coils connected in series or in parallel after lamination. Conventional stator windings such as electric motors have a very poor space factor due to the stator structure and winding method, and the space factor is generally only 45 to 65%. It was a drag on improving motor performance. Further, in the case of a stator structure with a complicated inner diameter, there is a problem that it cannot be applied to the stator. The laminated pyramid type, laminated truncated cone type or laminated curved type coil having different inner diameter shapes of the present invention can be applied to a complicated inner diameter shape, and the space factor is greatly improved to 70 to 85%. In addition, the magnetomotive force generated from the miniaturized and highly densified electromagnetic coil is greatly increased by improving the coil dimensional accuracy, and the cost can be reduced by increasing the torque of the motor, improving the response speed, and improving the dimensional accuracy.

  Perform alpha winding with different inner diameter shape and number of turns on a rectangular or circular shape using a fusion wire, and heat at least one of the thickness direction and the direction orthogonal to the thickness direction with heating By pressing, the gaps between the windings are brought into close contact, and by pressing, there is no distortion of the electromagnetic coils, and there is no gap between the coils when the coils are laminated, resulting in excellent dimensional accuracy and no deterioration of insulation. It was realized. In addition, a laminated electromagnetic coil is provided that is in close contact with a complicated stator of an electric motor without gaps by pressing and curving at least one of a thickness direction and a direction orthogonal to the thickness direction.

  FIG. 1 shows a three-dimensional view of a plurality of alpha-winding laminated electromagnetic coils having different inner diameter shapes using the fusion conducting wire of the present invention. Reference numeral 1 denotes a fused lead wire, 2 denotes a different inner diameter shape, 3 denotes a lead wire, 4 denotes a laminated surface, 5 denotes a cross section, and 6 denotes a connecting portion.

  FIG. 2 shows a three-dimensional view of a conventional alpha-wound air-core wound electromagnetic coil. Reference numeral 7 denotes a fused lead, 8 denotes an inner diameter shape, 9 denotes a lead wire, 10 denotes a laminated surface, and 11 denotes a connecting portion.

FIG. 3 is a cross-sectional view of a truncated cone and truncated pyramid shaped laminated electromagnetic coil according to the present invention, wherein 12 is a fused conductor, 13 is a laminated surface, and 14 is a different inner diameter shape. FIG. 4 is a cross-sectional view of the inner diameter shape of the laminated electromagnetic coil described above, wherein 15 is a fusion-bonding wire, 16 is a laminated surface, and 17 is a different inner diameter shape. FIG. 5 is a cross-sectional view of an alpha-winding truncated cone and a truncated pyramid-shaped laminated electromagnetic coil having different conductor diameters or conductor cross-sectional areas, 18 is a fused conductor, 19 is a laminated surface, and 20 is a different inner diameter.

  FIG. 6 is a cross-sectional view of a curved laminated electromagnetic coil according to the present invention, in which 21 is a fusion-bonding wire, 22 is a laminated surface, and 23 is a different inner diameter shape. FIG. 7 is a cross-sectional view of a laminated electromagnetic coil having a truncated cone shape and a truncated pyramid shape according to the present invention, in which 24 is a fusion conducting wire, 25 is a laminated surface, and 26 is a different inner diameter shape.

  An electromagnetic coil with an alpha winding of a fusion lead is attached to a pressure jig and pressed in at least one of the thickness direction and the direction orthogonal to the thickness direction to reduce the gap and closely adhere between the fusion wires. 8 is a cross-sectional view of the alpha winding coil before pressing, and FIG. 9 is a cross-sectional view of the alpha winding coil after pressing. 27 is a conductor, 28 is an insulating film, 29 is a fusion film, and 30 is between the conductors. , 31 indicates a fusion resin.

  FIG. 9 is a cross-sectional view of the electromagnetic coil after pressing as a means for heating the electromagnetic coil by heating to 60 to 230 ° C. with energization, hot air and infrared rays and heating and pressing with a pressing jig.

FIG. 9 is a cross-sectional view of the electromagnetic coil after heating and pressing, in which the electromagnetic coil is mounted on a mold heated to 60 to 230 ° C. and pressed to reduce the gap and bring the fused wires into close contact with each other.

  Furthermore, the balance degree of the alpha-winding laminated electromagnetic coil of the present invention approximates the accuracy of the pressing die, and therefore the gap portion is greatly reduced, so that the dimensional accuracy of the electromagnetic coil can be remarkably improved and the density can be increased.

  The air-core laminated electromagnetic coil of different alpha winding inner diameter shape of the present invention is formed into a truncated cone shape and a truncated cone shape respectively for the outer diameter and inner diameter, and when the electromagnetic coil is used as a stator coil having a complicated shape for an electric device, particularly an electric motor, High-precision coil dimensions, less variation, and higher density of electromagnetic coils. High-density electromagnetic coils increase torque due to increased magnetomotive force, improve response speed, and improve dimensional accuracy to reduce size and cost. Can be provided.

FIG. 3 is a three-dimensional view of an alpha wound laminated electromagnetic coil having a different inner diameter shape according to the present invention. Conventional alpha winding air core electromagnetic coil three-dimensional view. The cross section of the lamination | stacking electromagnetic coil of this invention. Sectional drawing of the laminated electromagnetic coil from which the internal diameter shape of this invention differs. Sectional drawing of the alpha winding lamination | stacking electromagnetic coil from which the conducting wire diameter or cross-sectional area of this invention differs. Sectional drawing of the laminated electromagnetic coil which carried out the bending process of this invention. Sectional drawing of the lamination | stacking electromagnetic coil whose internal diameter shape of this invention is a truncated cone shape and a truncated pyramid shape. Sectional drawing before the body process of the alpha winding single coil of this invention. Sectional drawing after the heating pressurization of the alpha winding single coil of this invention.

Explanation of symbols

1, 7, 12, 15, 18, 21, 24 Fused conductors 2, 14, 17, 20, 23, 26 Different inner diameter shapes 3, 9 Lead wires 4, 10, 13, 16, 19, 22, 25 Laminated Surface 5 Sections 6 and 11 Connection portion 8 Inner diameter 27 Conductor 28 Insulating film 29 Fusion film 30 Gap 31 between conductors Fusion resin

Claims (7)

An alpha winding having a different inner diameter and an air core winding having an arbitrary number of turns is provided with a conductive wire, an insulating coating covering the periphery of the conductive wire, and a fusion coating further covering the periphery of the insulating coating. A laminated electromagnetic coil characterized in that a plurality of electromagnetic coils are bonded together so that part or all of the inner diameter shape is a truncated cone or a truncated pyramid. The laminated electromagnetic coil according to claim 1, wherein an arbitrary number of air-core wound electromagnetic coils are bent and bonded together, or a plurality of electromagnetic coils are bonded and then bent to form a curved shape. 3. The laminated electromagnetic coil according to claim 1, wherein a plurality of air-core wound electromagnetic coils having different inner diameter shapes of alpha windings having different conductor diameters or conductor cross-sectional areas are bonded together. 4. The air core electromagnetic coil is heated and pressed in at least one of a thickness direction of the air-core electromagnetic coil and a direction orthogonal to the thickness direction within an elastic deformation range of the conducting wire. Laminated electromagnetic coil.   The heating means is configured to heat the electromagnetic coil by any one or a combination of energizing the electromagnetic coil and resistance heating, attaching the electromagnetic coil to a heated mold, or heating the electromagnetic coil with infrared rays or hot air. Item 5. The laminated electromagnetic coil according to Item 4. 5. The laminated electromagnetic according to claim 1, wherein a plurality of air-core wound electromagnetic coils having different inner diameter shapes of alpha windings having different conductor diameters or conductor cross-sectional areas are bonded together and connected in parallel or in series. coil. A part of an air-core wound electromagnetic coil having a winding lead wire having an inner diameter shape and an alpha winding having a lead wire, an insulating coating covering the periphery of the conductive wire, and a fusion coating further covering the periphery of the insulating coating Alternatively, a method of manufacturing a laminated electromagnetic coil, wherein all of the electromagnetic coils are bent and bonded together, or a plurality of electromagnetic coils are bonded together, and then bent by heating and pressing pressure.

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