JP2008187877A - Rotary electric machine, and manufacturing method of field coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a field coil 3 capable of improving the flexibility of positioning of a coil end portion to be pulled out from the field coil 3 formed by winding a flat wire 4 in an edgewise direction. <P>SOLUTION: A single flat wire 4 is wound in an edgewise direction to form two field coils 3 connected in series. For the two field coils 3, any one coil end portion 3a is pulled out in a tangential direction starting at an arbitrary point to be set between a rounded starting and end points formed on corners of a boss portion 2a in a state where the field coil 3 is assembled to a magnetic pole 2, and it has a predetermined inclination (inclined angle θ1) for the axial direction of the magnetic pole 2. Similarly, the other coil end portion 3b is pulled out in a tangential direction starting at an arbitrary point to be set between a rounded starting and end points formed on corners of the magnetic pole 2 in a state where the field coil 3 is assembled to a magnetic pole 2, and it has a predetermined inclination (inclined angle θ2) for the axial direction of the magnetic pole 2. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a field coil formed by winding a rectangular wire in an edgewise direction, and a method for manufacturing the field coil.

Conventionally, a field coil formed by winding a rectangular wire in an edgewise direction is known (see Patent Document 1 and Patent Document 2).
The manufacturing method of this field coil is demonstrated based on FIG.
First, as shown in FIG. 5A, both ends of one flat wire 100 are set on the core 110, respectively.
Subsequently, as shown in FIGS. 4B to 4D, the rectangular wire 100 is wound around the core 110 in the edgewise direction while the core 110 is rotated.
By winding up a predetermined number of times, two coil bodies connected by the connecting portion 120 are formed, as shown in FIG. Further, as shown in FIG. 5 (f), two field coils 130 connected in series are completed by folding back two coil bodies at the connecting portion 120.
JP 2006-271121 A Japanese Patent Publication No. 4-49336

As shown in FIG. 6, the field coil manufactured by the above method has a straight end at the winding start (referred to as coil end 140) and is fitted to the magnetic pole 150 (see FIG. 7). Thus, it is drawn straight upward in the figure. For this reason, as shown in FIG. 7, when the coil end 140 and the brush 160 are electrically connected, if the positions of the coil end 140 and the brush 160 are shifted in the circumferential direction, the coil end 140. Needs to be bent toward the brush. However, since a large load is required to bend the rectangular wire 100 in the edgewise direction, if the coil end portion 140 is bent after forming the coil body, the formed coil body may be deformed or coated. When using an attached coil, the coating may be broken.
In the manufacturing method described above, two field coils 130 are connected in series from one rectangular wire 100. In this case, when assembling the molded field coil 130 to the magnetic pole 150, it is necessary to fit two continuous field coils 130 to the outer periphery of the magnetic pole 150 at the same time, and thus high dimensional accuracy is required.

For the above reason, the method of bending the coil end portion 140 after forming the coil body is not adopted, and the coil end portion 140 is used in a straight shape. In this case, since the position of the coil end portion 140 is limited (positional freedom is small), if the positions of the coil end portion 140 and the brush 160 are shifted in the circumferential direction, they are electrically connected. For this reason, a separate member is required, which increases the number of parts and increases the cost.
The present invention has been made based on the above circumstances, and an object of the present invention is to provide a rotating electrical machine capable of improving the position freedom of a coil end portion drawn from a field coil formed by winding a rectangular wire in an edgewise direction. And a method of manufacturing a field coil.

(Invention of Claim 1)
The present invention is a rotating electrical machine having a field coil formed by winding a rectangular wire in an edgewise direction, the field coil being assembled to a magnetic pole and fixed to the inner periphery of a yoke, The at least one coil end is drawn in a tangential direction starting from an arbitrary point set between the start point and end point of the R shape formed at the corner of the magnetic pole, and has a predetermined value with respect to the axial direction of the magnetic pole. It has an inclination.
According to the above configuration, by arbitrarily selecting one point on R that is the starting point in the tangential direction, the drawing direction of the coil end can be appropriately changed, so that the degree of freedom of position of the coil end is improved.

(Invention of Claim 2)
The present invention has two field coils (a first field coil and a second field coil) formed by winding one rectangular wire from both sides in an edgewise direction and connected in series. A rotating electric machine in which the two field coils are assembled to the magnetic poles and fixed to the inner periphery of the yoke, and at least one coil end of the two field coils is at the corner of the magnetic pole. It is drawn in a tangential direction from an arbitrary point set between the start point and end point of the R shape to be formed, and has a predetermined inclination with respect to the axial direction of the magnetic pole.
According to the above configuration, by arbitrarily selecting one point on R that is the starting point in the tangential direction, the drawing direction of the coil end can be appropriately changed, so that the degree of freedom of position of the coil end is improved.

(Invention of Claim 3)
2. A rotating electrical machine according to claim 1, wherein a field coil is manufactured by setting an end portion of a flat wire to a core and winding the flat wire around the core in a coil shape while rotating the core. When the field coil is assembled to the magnetic pole and the angle formed between the direction in which the coil end is drawn and the axial direction of the magnetic pole is referred to as the inclination angle, the flat wire is between the winding core and the winding core. It is set on the core in a state having an angle corresponding to the inclination angle in advance, and a field coil is manufactured by winding a rectangular wire around the core while maintaining the set state. .

  According to the above method, since the angle corresponding to the inclination angle is given at the stage of setting the end of the flat wire to the core, the flat wire is wound around the core from this state to form a coil. By forming, a coil end having a predetermined inclination with respect to the axial direction of the magnetic pole can be formed simultaneously with forming the coil shape. Thereby, since it is not necessary to bend the end portion of the coil after forming the flat wire into a coil shape, the formed coil shape is not deformed, and a field coil with high dimensional accuracy can be manufactured. Moreover, when using a coil with a coating, there is no possibility that the coating is broken.

(Invention of Claim 4)
3. The rotating electrical machine according to claim 2, wherein both ends of the flat wire are respectively set on a core, and the flat wire is wound around the core in a coil shape while rotating the core from both sides of the flat wire. When a field coil is assembled to a magnetic pole and the angle formed between the direction in which the coil end is drawn out and the axial direction of the magnetic pole is referred to as an inclination angle, Is set on the core in a state where an angle corresponding to an inclination angle is previously provided between at least one end and the core, and a rectangular wire is placed around the core while maintaining the set state. A field coil is manufactured by winding.

  According to the above method, since the angle corresponding to the inclination angle is given at the stage of setting at least one end of the flat wire to the core, the flat wire is wound around the core from this state. By forming the coil shape, the coil end portion having a predetermined inclination with respect to the axial direction of the magnetic pole can be formed simultaneously with the forming of the coil shape. Thereby, since it is not necessary to bend the end portion of the coil after forming the flat wire into a coil shape, the formed coil shape is not deformed, and a field coil with high dimensional accuracy can be manufactured. Moreover, when using a coil with a coating, there is no possibility that the coating is broken.

  The best mode for carrying out the present invention will be described in detail with reference to the following examples.

1A is a development view of the yoke ASSY, FIG. 1B is a cross-sectional view taken along the line AA, and FIG. 2 is a plan view in the axial direction of the yoke ASSY.
The rotating electrical machine of the present embodiment is, for example, a starter motor for starting an automobile engine, and includes a yoke ASSY shown in FIGS. 1 and 2.
The yoke assembly is composed of a yoke 1 forming a magnetic circuit, four magnetic poles 2 fixed to the inner periphery of the yoke 1, and four field coils 3 assembled to each magnetic pole 2.

The yoke 1 is formed by rolling an iron plate, which is a ferromagnetic material, into a cylindrical shape.
As shown in FIG. 1B, the magnetic pole 2 is provided with a boss portion 2 a into which the field coil 3 is fitted and a flange portion 2 b that holds the field coil 3 between the yoke 1. As shown in FIG. 1A, the boss portion 2a has a rectangular cross-sectional shape and a corner portion is chamfered into an R shape.
The four field coils 3 are connected in 2 series-2 parallel. That is, two sets of two field coils 3 connected in series are provided, and the two sets are connected in parallel. The field coil 3 is formed by winding a rectangular wire 4 (see FIG. 3) in an edgewise direction by a manufacturing method described later.

  In the two field coils 3 connected in series, as shown in FIG. 1A, one coil end 3a on the upstream side in the direction of current flow is connected to the motor lead plate 5, and the current flows. The other coil end 3 b which is the downstream side in the flowing direction is connected to the lead wire 6 a (pigtail) of the positive electrode brush 6. However, one coil end 3a is in a state where the field coil 3 is assembled to the magnetic pole 2 (the state shown in FIG. 1), between the R-shaped start point and end point formed at the corner of the boss 2a. It is drawn in the tangential direction from an arbitrary set point as a starting point, and has a predetermined inclination (referred to as an inclination angle θ1) with respect to the axial direction (vertical direction in the figure) of the magnetic pole 2.

Similarly, the other coil end 3b is an arbitrary point set between an R-shaped start point and an end point formed at the corner of the boss 2a with the field coil 3 assembled to the magnetic pole 2. Starting from the tangential direction and has a predetermined inclination (referred to as an inclination angle θ2) with respect to the axial direction of the magnetic pole 2.
As shown in FIG. 2, the motor lead plate 5 is held by a grommet 7 fixed between a yoke 1 and an end frame (not shown), and is taken out from one end of the motor. The part is connected to a motor terminal of an electromagnetic switch (not shown).

Next, a method for manufacturing the field coil 3 will be described with reference to FIG.
First, one rectangular wire 4 having a predetermined length sufficient to manufacture two field coils 3 is prepared, and both ends of the rectangular wire 4 are respectively wound around the core 8 as shown in FIG. Set to. At this time, one end (left side in the drawing) of the flat wire 4 is set to the core 8 in advance with an angle α1 corresponding to the inclination angle θ1 between the flat wire 4 and the other end of the flat wire 4. The end is set on the core 8 in a state having an angle β1 corresponding to the inclination angle θ2 between the end 8 and the core 8 in advance. The left and right winding cores 8 are provided in the same shape as the boss 2a of the magnetic pole 2, respectively.

Subsequently, while the above set state is held by a clamping device (not shown), the cores 8 on both the left and right sides are respectively rotated (rotated right in the figure) as shown in FIGS. The rectangular wire 4 is wound around the winding core 8 in the edgewise direction.
After winding up a predetermined number of times, as shown in FIG. 5E, a bending jig 9 is applied to the connecting portion 3c that connects the two coil bodies, and the jig 9 is bent in the direction indicated by the arrow. . As a result, as shown in FIG. 5F, two field coils 3 connected in series via the connecting portion 3c are completed. The two field coils 3 are provided on the same side with respect to the connecting portion 3c, for example, as shown in FIG. The illustrated arrows indicate the flow direction of the magnetic flux.
Thereafter, the entire coil is curved so that the two field coils 3 can be arranged along the inner periphery of the yoke 1, and the process is finished.

(Effect of Example 1)
According to the above manufacturing method, the angles α1 and β1 corresponding to the inclination angles θ1 and θ2 are provided at the stage where both ends of the flat wire 4 are set on the core 8, respectively. The coil ends 3a and 3b having the inclination angles θ1 and θ2 can be formed at the same time as the coil-shaped portion fitted to the boss 2a of the magnetic pole 2 by winding the rectangular wire 4 around. In this case, since it is not necessary to bend the coil end portions 3a and 3b after the winding process, the coil-shaped portion fitted to the boss portion 2a of the magnetic pole 2 and the coil end drawn from the coil-shaped portion The positional dimensional accuracy with the parts 3a and 3b can be manufactured with high accuracy. Moreover, when using a coil with a coating, there is no possibility that the coating is broken. Thereby, it is not necessary to electrically connect between the one coil end 3a and the motor lead plate 5 and between the other coil end 3b and the lead wire 6a of the positive electrode brush 6 by another member. The cost can be reduced by reducing the number of parts.

Further, when two field coils 3 connected in series from one rectangular wire 4 are manufactured, a pitch error between two poles is included as compared with the case where one field coil 3 is manufactured. Therefore, higher dimensional accuracy is required. On the other hand, in this embodiment, not only can the position accuracy of the coil-shaped portion and the coil end portions 3a, 3b drawn from the coil-shaped portion be manufactured with high accuracy, but the coil-shaped portion is not collapsed. Since it does not occur, high dimensional accuracy can be ensured.
Furthermore, according to the manufacturing method of the present embodiment, only by changing the angles α1 and β1 for setting both ends of the flat wire 4 to the winding core 8, the coil end portions 3a and 3b are pulled out (inclination angles θ1 and θ2). ) Can be set arbitrarily, improving the degree of design freedom.

FIG. 4 is a manufacturing process diagram of the field coil 3.
The second embodiment is an example in which one field coil 3 and the other field coil 3 are wound symmetrically. In this case, as shown in FIG. 4A, an angle α1 for setting one end of the flat wire 4 to the core 8 and an angle β1 for setting the other end of the flat wire 4 to the core 8. Are the same angle (α1 = β1), and as shown in FIGS. 4B to 4D, the cores 8 on both the left and right sides are rotated in opposite directions, and the rectangular wire 4 is formed around the core 8. Wind up.
After winding up a predetermined number of times, as shown in FIG. 5E, a bending jig 9 is applied to the connecting portion 3c that connects the two coil bodies, and the jig 9 is bent in the direction indicated by the arrow. . As a result, as shown in FIG. 5F, the two field coils 3 connected in series via the connecting portion 3c are made symmetrical. The two field coils 3 are provided, for example, at positions facing each other across the connecting portion 3c, as shown in FIG. The illustrated arrows indicate the flow direction of the magnetic flux.

(Modification)
In the first embodiment and the second embodiment, one example of manufacturing two field coils 3 connected in series from one flat wire 4 is described. However, one field coil is formed from one flat wire 4. 3 can be manufactured by the same method as in the above embodiment.
In the first and second embodiments, both the one coil end 3a and the other coil end 3b are provided with inclination angles θ1 and θ2, but only one coil end 3a or the other coil end 3a is provided. Only the coil end 3b can be manufactured to have an inclination angle.

(A) Development view of yoke assembly, (b) AA sectional view. It is an axial direction top view of yoke ASSY. It is a manufacturing-process figure of a field coil (Example 1). It is a manufacturing-process figure of a field coil (Example 2). It is a manufacturing-process figure of the field coil by a prior art. It is a perspective view of a field coil (prior art). It is a development view of the yoke assembly (prior art).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Yoke 2 Magnetic pole 2a Boss part of magnetic pole 3 Field coil 3a One coil end part 3b The other coil end part 4 Rectangular wire 8 Winding core

Claims (4)

Having a field coil formed by winding a flat wire in an edgewise direction;
A rotating electrical machine in which this field coil is assembled to a magnetic pole and fixed to the inner periphery of the yoke,
The field coil has at least one coil end portion drawn out in a tangential direction starting from an arbitrary point set between a start point and an end point of an R shape formed at a corner portion of the magnetic pole. A rotating electrical machine characterized by having a predetermined inclination with respect to the axial direction. It has two field coils formed by winding one rectangular wire from both sides in the edgewise direction and connected in series.
A rotating electrical machine in which the two field coils are assembled to magnetic poles and fixed to the inner circumference of the yoke,
The two field coils have at least one coil end portion drawn in a tangential direction starting from an arbitrary point set between an R-shaped start point and an end point formed at the corner of the magnetic pole. A rotating electrical machine having a predetermined inclination with respect to the axial direction of the magnetic pole. In the rotating electrical machine according to claim 1,
A method of manufacturing the field coil by setting the end of the flat wire to a core and rotating the core while winding the flat wire around the core in a coil shape,
When the field coil is assembled to the magnetic pole and the angle formed between the direction in which the coil end is pulled out and the axial direction of the magnetic pole is called an inclination angle,
The flat wire is set on the core in a state where an angle corresponding to the inclination angle is provided between the flat core and the flat wire around the core while maintaining the set state. A method of manufacturing a field coil, wherein the field coil is manufactured by winding a wire. In the rotating electrical machine according to claim 2,
The two ends of the rectangular wire are set on a winding core, and the rectangular wire is wound around the winding core in a coil shape while rotating the winding core from both sides of the rectangular wire. A method of manufacturing a magnetic coil, comprising:
When the field coil is assembled to the magnetic pole and the angle formed between the direction in which the coil end is pulled out and the axial direction of the magnetic pole is called an inclination angle,
The flat wire is set on the core in advance with an angle corresponding to the tilt angle between at least one end and the core, and the winding is maintained while maintaining the set state. A field coil manufacturing method, wherein the field coil is manufactured by winding the rectangular wire around a core.

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