JP2008228541A - Coil, and method of manufacturing coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil enabling further reduction in the waste of a material, and to provide the coil, and an armature. <P>SOLUTION: The method includes: a first arrangement step of laminating a plurality of members 23<SB>1</SB>-23<SB>12</SB>which are arranged in a U-shape using wires 20<SB>1</SB>-20<SB>12</SB>, 21<SB>1</SB>-21<SB>12</SB>as one side and of which at least one side is opened by aligning the opened one side; a second arrangement step of arranging a plurality of coil raw materials in the opened area after lamination so that laminated U-shaped members 23<SB>1</SB>-23<SB>12</SB>are consecutively linked to one another; and a connection step of connecting all wires 20<SB>1</SB>-20<SB>12</SB>, 21<SB>1</SB>-21<SB>12</SB>so that they are continuously electrically linked to one another. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a coil used for a motor or a generator and a method for manufacturing the coil.

  2. Description of the Related Art In recent years, an electric motor used for an electric vehicle or a hybrid vehicle is composed of a cylindrical stator, a columnar rotor arranged inside the stator, and a shaft connected to the rotor. As this stator, a configuration in which a rectangular wire is wound around a stator iron core around an internal tooth (tooth) of an internal tooth-shaped stator core is disclosed (for example, see Patent Document 1).

  The coil disclosed in Patent Document 1 is punched into a U-shape by pressing a copper plate 126 as shown in FIG. 27, and four of the U-shaped copper plates are laminated to form a coil shown in FIG. The coil 114 shown in a) is created. After insulating the surface of the coil 114 (see FIG. 28B), an adhesive is applied to the surface (see FIG. 28C), and a plurality of coils 114 are bonded. A perspective view of the multilayer coil 112 in a state where a plurality of coils 114 are laminated and bonded together is shown in FIG.

The laminated body coil 112 is inserted into the slots 146 and 148 of the stator core 102 as shown in FIGS. Then, in order to connect the U-shaped members adjacent from above as shown in FIG. 30 (c), a wire rod is inserted into the open portion, and a coil is mounted on the stator iron core.
2005-137174 gazette

  However, since the coil 114 is formed by pressing the copper plate 126 in the above prior art, a portion to be discarded is generated in the copper plate 126, and the material is wasted. Further, since the copper plate is expensive, the cost for producing the coil 114 has been high.

  An object of the present invention is to provide a coil manufacturing method and a coil capable of further reducing waste of materials in consideration of the problems of the conventional coil manufacturing method.

In order to achieve the above object, the first present invention provides:
A member in which the cut coil material is arranged corresponding to each side of the polygonal shape with at least one side open, or a member formed by bending one coil material into a predetermined shape with at least one side open is the above-mentioned opening A first arrangement step of stacking a plurality of aligned one sides;
A second arrangement step of arranging a plurality of coil materials so that the laminated members are continuously connected to the opened portion after the lamination;
A connection step in which all the coil materials arranged in a continuous manner are connected so as to be continuously electrically connected at all or part of the contact surfaces where both ends of each of the coil materials contact each other. And a method of manufacturing a coil.

The second aspect of the present invention is
The member formed by bending the one coil material into a predetermined shape with at least one side open is a member obtained by bending a flat wire into a U shape, and the laminated surface thereof is substantially flush with each other. It is a manufacturing method of the coil of the 1st present invention bent.

The third aspect of the present invention
A cutting step of cutting one or a plurality of types of rectangular wires to create a plurality of the coil materials;
A peeling step of peeling the insulating film at a predetermined portion of each of the both ends of the plurality of coil materials to form the contact surface;
The second arrangement step is a method of manufacturing a coil according to the first aspect of the present invention, which is a step of arranging the plurality of coil materials so that the contact surfaces face each other.

The fourth aspect of the present invention is
The predetermined portion is the coil manufacturing method according to the third aspect of the present invention, which is a portion on the laminated surface side of the both ends of the coil material.

The fifth aspect of the present invention is
The member is a member arranged in a polygonal shape with at least one side open, with the coil material as one side,
The polygonal shape in which at least one side is open is a quadrangular shape having two pairs of opposing sides as a first set and a second set, with one side of the second set missing,
The peeling step includes
Preparing the coil material corresponding to each side of the square shape,
The thickness of the predetermined portion of the coil material arranged as a pair of sides of the first set in the quadrangular shape is reduced from the center side to the end side in the longitudinal direction of the coil material. A first cutting step of cutting the vicinity of both ends of one surface of each coil material of one set to form the contact surface;
The thickness of the predetermined part of the coil material arranged as a pair of sides of the second set in the quadrangular shape is reduced from one end to the other end along the width direction of the coil material. A second cutting step of cutting the vicinity of both ends of one surface of the coil material of each of the second set to form the contact surface;
In the first arrangement step and the second arrangement step, the contact surfaces in the pair of sides of the first set and the contact surfaces in the pair of sides of the second set are opposed to each other. The coil manufacturing method according to the fourth aspect of the present invention is a step of arranging the coil material.

The sixth aspect of the present invention
The first cutting step includes
A step forming step for forming a step on the center side of the predetermined portion of the coil material arranged as a pair of sides of the first set;
In the first arrangement step and the second arrangement step, the other end along the width direction of the predetermined portion of the coil material arranged as a pair of sides of the second set is the first arrangement step. It is a manufacturing method of the coil of the 5th present invention which is a process of arranging the plurality of coil materials so that it may touch the level difference of a pair of coil materials of one set.

The seventh aspect of the present invention
After the first arrangement step, the method further includes an insertion step of inserting a pair of sides of the first set of the quadrangular members into slots of the stator or the rotor,
It is a manufacturing method of the coil of the 5th present invention in which the 2nd arrangement process is performed after the insertion process.

Further, the eighth aspect of the present invention is
The cutting step includes a step of cutting a plurality of types of rectangular wires having the same cross-sectional area and different thicknesses and widths, and preparing a plurality of types of the coil material used for the pair of sides of the first set,
The first arrangement step includes
The coil material cut from one type of the rectangular wire is disposed so as to form a pair of sides of the first set of one of the quadrangular members,
In the first set, a plurality of the rectangular wires arranged on the other side are smaller than the rectangular wires arranged on one side with respect to the stacking direction so that the width is smaller. It is a manufacturing method of the coil of the 5th present invention which is a process of arranging a coil material.

The ninth aspect of the present invention provides
The member formed by bending the one coil material into a predetermined shape with at least one side open is a member obtained by bending a flat wire into a U shape,
Further comprising a bending step of bending the coil material into a U-shape so that the laminated surfaces are substantially flush with each other,
The peeling step includes
A step of preparing the coil material for forming the U-shaped member, and the coil material to be disposed in the opened part,
Near both ends of one surface of the coil material such that the thickness of the predetermined portion of the coil material forming the U-shaped member becomes thinner from the center side to the end side in the longitudinal direction of the coil material Cutting A step for forming the contact surface, and the thickness of the contact surface portion of the coil material disposed in the opened part is from one end to the other end along the width direction of the coil material. Cutting the vicinity of both ends of one surface of the coil material so as to be thin, and a cutting B step for forming the contact surface,
In the second arrangement step, the contact surface of the coil material formed on the U-shaped member and the contact surface of the coil material disposed on the opened portion are opposed to each other. A coil manufacturing method according to a fourth aspect of the present invention, wherein a plurality of the coil materials are arranged.

The tenth aspect of the present invention is
The cutting A step includes
A step forming step of forming a step on the center side of the predetermined portion of the coil material forming the U-shaped member;
In the second arrangement step, the other end of the coil material arranged in the open part along the width direction in the predetermined part forms the U-shaped member. It is a manufacturing method of the coil of the 9th present invention which is a process of arranging the plurality of coil materials so that it may contact the level difference.

The eleventh aspect of the present invention is
After the first arrangement step, further comprising an insertion step of inserting a pair of opposing sides of the U-shaped member into a slot of the stator or rotor,
It is a manufacturing method of the coil of the 9th present invention in which the 2nd arrangement process is performed after the insertion process.

The twelfth aspect of the present invention is
The cutting step includes a step of cutting a plurality of types of rectangular wires having the same cross-sectional area and different thicknesses and widths, and preparing a plurality of types of the coil material used for the U-shaped member,
The first arrangement step includes
The rectangular wire forming the U-shaped member arranged on the other side is more preferable than the flat wire forming the U-shaped member arranged on the one side with respect to the stacking direction. The method for manufacturing a coil according to the ninth aspect of the present invention is a step of arranging a plurality of the coil materials so that the width is reduced.

The thirteenth aspect of the present invention is
The second arranging step is a step of arranging the plurality of coil materials so that the contact surfaces face each other.
It is a manufacturing method of the coil of the 1st present invention provided with the crevice formation process which forms a crevice in at least one above-mentioned contact surface among the contact surfaces arranged facing.

The fourteenth aspect of the present invention is
A pretreatment step of applying a brazing or a cream-like member containing a conductive material to the inside of the recess,
The connecting step includes
A process of melting all the coil materials by energizing all the coil materials to cause heat generation, and connecting all the coil materials so as to be electrically connected via all or part of the contact surfaces. A coil manufacturing method according to the thirteenth aspect of the present invention.

The fifteenth aspect of the present invention is
The pretreatment step includes
It is a manufacturing method of the coil of 14th this invention which is the process of apply | coating the said wax or the said cream-like member so that it may be the quantity below the volume of the said recessed part, and may protrude rather than the said recessed part.

The 16th aspect of the present invention is
The manufacturing of the coil of the thirteenth aspect of the present invention, comprising an insulating film forming step of forming an insulating film around the concave portion of the one contact surface and a portion of the other contact surface facing the concave portion. Is the method.

The seventeenth aspect of the present invention is
Cutting one or a plurality of types of rectangular wires, and creating a plurality of the coil materials,
The insulating coating step is a method of manufacturing a coil according to the sixteenth aspect of the present invention, which is a step of simultaneously forming an insulating coating on the cut surface of the coil material.

The 18th aspect of the present invention is
A pretreatment step of preliminarily brazing or applying cream solder containing a conductive material to the contact surface;
The connecting step includes
The first step is to melt the solder by energizing all the coil materials to generate heat, and to connect all the coil materials so as to be electrically connected via all or part of the contact surface. It is the manufacturing method of the coil of this invention.

The nineteenth aspect of the present invention
In the fourteenth or eighteenth method of manufacturing a coil according to the present invention, the main component of the solder is any one of solder, gold, silver, and copper.

The twentieth aspect of the present invention is
In the fourteenth or eighteenth aspect of the present invention, the cream-like member is cream solder.

The 21st aspect of the present invention provides
Cutting one or a plurality of types of rectangular wires, and creating a plurality of the coil materials,
The first arrangement step is a method of manufacturing a coil according to the first aspect of the present invention, which is a step of arranging the coil material so that the contact surface faces the cut surface as the contact surface.

The twenty-second aspect of the present invention provides
The connection step is a step of connecting so that both ends of the coil material are electrically connected continuously using a conductive adhesive,
It is a manufacturing method of the coil of the 1st present invention in which the connection process is performed in the case of the 2nd arrangement process.

The twenty-third aspect of the present invention provides
A laminated member in which a plurality of members arranged in a polygonal shape in which at least one side is open, and a coil material as one side,
A plurality of coil materials for transition arranged in the opened site,
It is a coil in which both end portions of all the coil element sides are continuously electrically connected.

The twenty-fourth aspect of the present invention provides
A laminated member in which a plurality of members formed by bending one coil material is laminated so as to have a predetermined shape with at least one side open;
A plurality of coil materials for transition arranged in the opened site,
It is a coil in which both end portions of all the coil element sides are continuously electrically connected.

The twenty-fifth aspect of the present invention provides
The continuous electrical connection means that one open end and the other open end of the laminated coil sides are continuously electrically connected. It is a coil of this invention.

The twenty-sixth aspect of the present invention provides
The member is a member according to a twenty-fourth aspect of the present invention, wherein the member is a member in which a flat wire is bent into a U shape, and the laminated surface is bent so as to be substantially on the same plane.

The twenty-seventh aspect of the present invention provides
The coil material has a contact surface that comes into contact with the other coil material to electrically connect with the other coil material;
The coil material according to the twenty-third or twenty-fourth aspect of the present invention, wherein the coil materials are connected by a conductive member at all or a part of the contact surfaces arranged to face each other.

The twenty-eighth aspect of the present invention provides
The coil material has a contact surface that comes into contact with the other coil material to electrically connect with the other coil material;
The coil according to the 23rd or 24th aspect of the present invention, wherein a concave portion is formed on at least one of the contact surfaces arranged to face each other between the connected coil materials.

The 29th aspect of the present invention provides
The coil of the twenty-eighth aspect of the present invention, wherein an insulating film is formed around the concave portion of the one contact surface and around a portion of the other contact surface facing the concave portion.

The 30th aspect of the present invention
The coil according to the twenty-eighth aspect of the present invention, wherein the conductive member is present in the recess.

  According to the present invention, it is possible to provide a coil manufacturing method and a coil that can further reduce waste of materials in consideration of the problems of the conventional coil manufacturing method.

  Embodiments according to the present invention will be described below with reference to the drawings.

(Embodiment 1)
Hereinafter, the coil according to the first embodiment of the present invention will be described, and the stator 1 using the coil according to the first embodiment will be described at the same time. FIG. 1 is a perspective view of the stator 1. FIG. 2A is a plan view of the stator 1, and FIG. 2B is a side view of the stator 1.

  As shown in FIGS. 1, 2 (a), and 2 (b), the stator 1 includes a cylindrical stator iron core 2 and 18 coils 10. The stator iron core 2 has 18 slots 3 in a direction parallel to the central axis 2 a and 18 teeth 4 between the slots 3. The coils 10 are inserted into the slots 3 at both ends of the teeth 4 so as to be wound around the teeth 4 one by one, and are attached to the stator iron core 2.

  Next, the configuration of the coil 10 will be described.

  FIG. 3 is a configuration perspective view of the coil 10. 4 (a) is a front view of the coil 10, FIG. 4 (b) is a top view of the coil 10, FIG. 4 (c) is a right side view of the coil 10, and FIG. 4 (d) is a left side of the coil 10. FIG. FIG. 4E is a rear view of the coil 10, and FIG. 4F is a bottom view of the coil 10. Here, the front view is a state in which the coil 10 is viewed from the position on the outer peripheral side of the stator 1 assuming that the coil 10 is mounted on the stator core 2. As shown in FIGS. 3 and 4 (a), the coil 10 is formed by connecting a plurality of flat wires at their ends so as to form a square shape when viewed from the front. As shown in FIGS. 3 and 4C, the coil 10 has one end portion 11 on the front side and the other end portion 12 on the back side.

End 11 is positioned at the upper end portion of the left side 14 ₁ constituting the rectangle when viewed from the front. The left side 14 ₁ of the end, the lower side 15 ₁ of the rectangles shape is electrically connected. Further, the lower side 15 _1, the right side 16 ₁ is connected. The left side 14 ₁ , the lower side 15 ₁ , the right side 16 _1, and the upper side 17 form one round of the rectangular coil 10.

The upper side 17 ₁ of the end of the first round, second round of the left side 14 ₂ are electrically connected, the lower side 15 ₂ similarly to the first round in the order, and the right side 16 ₂ and the upper side 17 ₂ is connected Yes. In this way, the first to eleventh rounds are formed. The lap 11 of the upper side 17 and _second end 12 lap left _{14 12,} the lower side _{15 12} and has right _{16 12} are connected, the end of the right side _{16 12} of the lap 12 has an end portion 12 . For this reason, the twelfth circle is composed of only the left side 14 ₁₂ , the lower side 15 _12, and the right side 16 ₁₂ , and the upper side is not connected. An example of the plurality of coil materials for transition according to the present invention corresponds to the upper sides 17 _{1 to} 17 ₁₁ .

Further, as shown in FIG. 4 (b), the first lap of the upper side 17 _1, 1 lap of the right side 16 ₁ and both ends to connect between the left side 14 ₂ of the second round (the right side 16 ₁ the connection portion) between the left side 14 ₂ are formed by bending so a step is formed. The upper sides 17 _{2 to} 17 ₁₁ are similarly bent and formed. In FIG. 4 (b), an end portion connected with the right side 16 ₁ of the upper edge 17 ₁ and E, magnified view both end portions are shown (to be described later is an end portion that is connected to the left side 14 ₂ as E'5 (See (b)).

Incidentally, the rectangular left 14 ₁ and the right side 16 ₁ of the first week of the coil 10 is constituted by a rectangular wire _{5 1} of the same thickness and width, which constitutes ₂ and the right side 16 ₂ of the second round left 14 The lines are different in width and thickness, and are composed of rectangular wires having different shapes for each circumference. Thus, the rectangular wire 5 ₁ to 5 _12, each of the circumference of the left and right sides of the coil 10 is formed. FIG. 5A is a cross-sectional view taken along the line XX ′ on the right sides 16 _{1 to} 16 ₁₂ shown in FIG. In FIG. 5A, the upper side is the front side of FIG. The flat wire ₅ 1 _{to 5 12} is the same cross-sectional area, in turn width 5w into the flat wire ₅ 1 _{to 5 12} is narrow, the thickness 5h is thicker. The thickness of each rectangular wire is set to 5 ₁ h to 5 ₁₂ h, and the width is set to 5 ₁ w to 5 ₁₂ w. The arrow D direction in FIG. 5 corresponds to an example of the stacking direction of the present invention. 5A and 5B, the upper side is the front side of the coil 10.

Further, each of the lower side 15 ₁ and the upper side 17 ₁ of the periphery of the coil 10 is constituted by a rectangular wire 25 ₁ of the same thickness and width, rectangular wire constituting the lower side 15 ₂ of the second round and the top side 17 ₂ 25 ₂ a, thickness is different, and a flat wire of different thicknesses for each peripheral. This way the flat wire ₂₅ to _{253 11,} the upper and lower sides to 1-11 lap is composed respectively by the flat wire _{25 12} 12 lap the lower side _{15 12} is constructed. As shown in the plan view of FIG. 5 (b), the thickness 25 h increases in order from the rectangular wires 25 _{1 to} 25 ₁₂ . The thickness of each flat wire is set to 25 ₁ h to 25 ₁₂ h. The length of the thickness 25 ₁ h is set to the same thickness as the thickness 5 ₁ h, and the length of the thickness 25 ₂ h is set to the same thickness as the thickness 5 ₂ h.

The widths of the rectangular wires 25 _{1 to} 25 ₁₂ are all the same size 25w. The flat wire 25 _to 253 ₁₂ because although the thickness becomes thick gradually widths are the same, the smallest cross-sectional area of the flat wire 25 _1. Sectional area of the rectangular wire 25 _1, for the same size of the current flowing through the left side _{14 1-14 12} and right ₁₆ 1 _{to 16 12} to be inserted into the slot, the cross-sectional area of the flat wire ₅ 1 _{to 5 12} It is over the size.

  Next, the connection structure of each side will be described.

6 (a) is an enlarged view of the connecting portion P of the right side 16 ₁ of the first round and the top side 17 ₁ (see FIG. 3). FIG. 6B shows a state in which the right side 16 ₁ and the upper side 17 ₁ are separated. As shown in FIG. 6B, the right end portion 17 ₁ R of the upper side 17 ₁ is formed on a tapered surface Q in which the thickness 25 ₁ h of the flat wire 25 decreases from the top to the bottom. Further, the upper end portion 16 1 _U of the right side 16 ₁ is formed into a tapered shape surface R where the flat wire 5 ₁ of thickness 5 _{1 h} from bottom to top thinner.

Further, as shown in FIG. 6B, a step T is provided below the tapered surface R. FIG. 6C is a side view showing a state in which the right side 16 ₁ and the upper side 17 ₁ are connected. As shown in FIG. 6 (c), the upper side 17 ₁ and the right side 16 _1, the tip QE of the upper side 17 ₁ of the tapered surface Q are connected so as to abut on the step T. This tip QE corresponds to an example of the other end along the width direction of the present invention. Further, the length 5 ₁ S of the portion where the longitudinal tapered surface R of the flat wire 5 ₁ (right side 16 ₁ ) is formed so that the tip QE contacts the step T is equal to the flat wire 25 ₁ (upper side). 17 ₁ ) is substantially the same length as the width 25 ₁ w.

FIG. 7 is a diagram illustrating a state in which the connection of the left side 14 ₁ , the lower side 15 ₁ , the right side 16 ₁ , and the upper side 17 _{1 in} the first round is released. As described above, the left side 14 ₁ and the right side 16 ₁ is formed by a flat wire _{5 1,} the lower side 15 ₁ and the upper side 17 ₁ is formed by a rectangular wire 25 _1. As shown in FIG. 7, the lower end portion 16 ₁ D of the right side 16 ₁ is formed with a tapered surface R in which the thickness 5 ₁ h of the flat wire 5 becomes thinner downward. A step T is formed on the tapered surface R of the lower end portion 16 ₁ D in the same manner as the upper end portion 16 ₁ U. Further, similarly to the right side 16 _1, the upper end portion 14 ₁ U and the lower end portion 14 ₁ tapered surface to D R and level difference T of the left side 14 ₁ is formed.

On the other hand, a tapered surface Q similar to that of the right end portion 17 ₁ R is also formed in the left end portion 17 ₁ L of the upper side 17 ₁ . Also, as is the lower side 15 ₁ of the left end portion 15 ₁ L and right end 15 ₁ R also tapered surface Q is formed, the thickness _{5 1} h is reduced upward in contrast to the upper 17 ₁ Is formed.

Left 14 ₁ shown in FIG. 7 is connected to the lower end portion 14 ₁ left end of the lower side 15 ₁ D 15 ₁ L. Lower 15 ₁ is connected with the lower end portion 16 ₁ D on the right side 16 ₁ in the right end portion 15 ₁ R, right 16 _1, connected at its upper end portion 16 ₁ U and the right end portion 17 ₁ R of the upper side 17 ₁ is doing. The left end portion 17 ₁ L of the upper side 17 ₁ is connected to the upper end portion 14 ₂ D of the left side 14 ₂ of the second turn (not shown). Thus, from the first lap of the left side 14 ₁ to 12 lap right side 16 _12, coil 10 is constituted by the respective sides are connected in this order in each of the end portions.

  Next, a state where the coil 10 is mounted on the stator core 2 will be described.

As described above, 18 coils 10 are mounted on the stator 1, and as shown in FIG. 2A, one slot 3 has left sides 14 _{1 to} 14 ₁₂ and right sides of adjacent coils 10. 16 _{1 to} 16 ₁₂ are inserted.

  FIG. 8 is a plan view of the stator 1 schematically showing the coil 10. Since the stator of FIG. 8 is a stator composed of three-phase coils of U phase, V phase, and W phase, each of the three coils 10 is connected, and each phase is composed of six coils 10. Will be.

  In FIG. 8, the connection 18 for the U phase is indicated by a dotted line. As shown in FIG. 8, in the six coils 10 constituting the U phase, the end portions 11 and the end portions are arranged so that the direction of current flow is opposite between the coils connected adjacently by the connection 18. 12 connections are made. That is, in the six coils 10 constituting the U phase, the end portions 11 or the end portions 12 are connected between adjacent coils. In FIG. 8, the current directions on the left and right sides of the coil 10 are shown. As the direction of this current, a circle with a cross indicates a vertical depth direction on the paper surface, and a circle with a circle indicates a vertical front side of the paper surface. Further, in FIG. 8, the coil 10 is illustrated by reducing the number of circumferences of the coil 10 for easy understanding.

An example of the coil material of the present invention corresponds to the left side 14 _{1 to} 14 ₁₂ , the lower side 15 ₁ to 15 ₁₂ , the right side 16 _{1 to} 16 ₁₂ , and the upper side 17 _{1 to} 17 ₁₁ of the present embodiment. An example of the polygonal shape of the present invention corresponds to the quadrangular shape of the present embodiment. Further, a first set of the present invention corresponds to, for example, the left side 14 ₁ and the right side 16 ₁ of the present embodiment. Also, a second set of the present invention corresponds to, for example, the upper side 17 ₁ and the lower side 15 ₁ of the present embodiment. Further, an example of the open end of the coil material of the present invention, the left 14 ₁ shown in FIG. 7 corresponds to the lower end portion 14 ₁ D and the upper end portion 14 ₁ U, the bottom side 15 _1, the left end portion 15 ₁ L and It corresponds to the right end portion 15 ₁ R, the right side 16 ₁ corresponds to the lower end portion 16 ₁ D and the upper end portion 16 ₁ U, and the upper side 17 ₁ corresponds to the right end portion 17 ₁ R and the left end portion 17 ₁ L.

(Embodiment 2)
Below, the manufacturing method of the coil in Embodiment 2 concerning this invention is demonstrated. This coil manufacturing method is a method for manufacturing a coil attached to the stator iron core 2 shown in FIG.

First, as shown in FIG. 9 (a), the cross-sectional shape is rectangular, the rectangular wire 25 ₁ insulating film is formed on the surface, the wire 24 ₁ for upper 17 ₁ shown in FIG. 3, It is cut into wire rod 20 ₁ of the length of the lower side 15 for _1. Incidentally, details will be described later, toward the wire 24 ₁ length than the wire 20 ₁ is formed longer. Further, the flat wire 5 is cut into two wire rods 21 ₁ having a length for the left side 14 ₁ and the right side 16 ₁ . The step of cutting the flat wires 5 ₁ and 25 ₁ corresponds to an example of the cutting step of the present invention. Here, the thickness of the wire 20 ₁ and 20 ₁ h, and the upper surface and 20 ₁ a, both end portions in the longitudinal direction and 20 ₁ b, the width 20 ₁ w. Also, the side surface in the width 20 ₁ w direction is 20 ₁ e. Similar to the wire 20 ₁ also wire 21 ₁ to ₂₁ 1 h, the top surface of ₂₁ 1 a, both end portions ₂₁ 1 b, width ₂₁ 1 w, the side surfaces of the width 21 ₁ w direction and 21 ₁ e the thickness . Further, similarly to the wire 20 ₁ also wire 24 _{1, 24} thickness 1 h, the top surface of ₂₄ 1 a, ₂₄ both end portions 1 b, the width ₂₄ 1 w, width 24 ₁ w direction side of the ₂₄ 1 e And An example of the laminated surface of the present invention corresponds to the upper surface 20 ₁ a, the upper surface 21 ₁ a, or the upper surface 24 ₁ a of the present embodiment.

Next, as shown in FIG. 9 (b), the wire 20 _1, wire 24 _1, the insulating coating of longitudinal ends of the wire 21 ₁ is peeled off. The end portions 20 ₁ b of the wire 20 _1, the upper surface 20 ₁ so that one side 20 ₁ e from the other side 20 ₁ e to a thickness 20 ₁ h to form a thinner such tapered surface Q gradually The a side is shaved. Similarly, the end portions 24 ₁ b of the wire 24 _1, the upper surface as one side 24 ₁ e from the other side 24 ₁ e to a thickness 24 ₁ h to form a thinner such tapered surface Q gradually 24 ₁ a side is shaved. Process thus cutting the wire 21 ₁ corresponds to an example of a cutting second step of the present invention.

In addition, for both end portions 21 ₁ b of the two wires 21 ₁ , the surface 21 ₁ a side is ground so as to form a tapered surface R such that the thickness 21 ₁ h gradually decreases toward the ends. It is done. Process thus cutting the wire 20 ₁ and the wire 24 ₁ corresponds to an example of cutting the first step of the present invention. Further, in the central end of the wire 21 _first tapered surface R, the step T is formed. This step corresponds to an example of the step forming step of the present invention. In this way, by cutting the wire rods 20 ₁ and 21 ₁ , the insulating films on the tapered surfaces Q and R and the step T are peeled off.

Incidentally, (corresponding to FIG. 6 (b) in length _{5 1} s mentioned) wire 21 ₁ in the longitudinal direction of the tapered surface R of the length ₂₁ 1 s, the width of the wire 20 ₁ and the wire 24 ₁ 20 ₁ w and 24 ₁ w (corresponding to the width 25 ₁ w described in FIG. 6B) are formed to have substantially the same length.

The step of cutting the wire on the tapered surfaces Q and R corresponds to an example of the peeling step of the present invention. An example of the predetermined portion of the present invention corresponds to both ends of the wires 20 ₁ and 21 ₁ , and an example of the contact surface of the present invention corresponds to the tapered surfaces Q and R of the present embodiment. .

Similar to the above, cutting the flat wire 25 _2, a wire 20 ₂ Length of the second round of the upper side 17 ₂ and the lower side 15 for _2, the wire 24 ₂ is formed, by cutting the flat wire _{5 2,} 2 wire 21 ₂ two circumferential th left 14 ₂ and the right side 16 for ₂ is created, tapered surface Q are formed at both ends of the wire 20 ₂ and wire 24 _2, tapered surfaces on both ends of the wire 21 ₂ R And a step T are formed. In this manner, it is disconnected from the flat wire ₂₅ to _{253 12,} tapered wire surface Q is formed ₂₀ 1 _{to 20 11} and the wire _{24 1-24 12} is created at both ends. Further, the flat wire ₅ 1 _{to 5 12} wire ₂₁ 1 _{to 21 12} to tapered surface R and the step T is formed on both ends is cut from is created.

Then, the wire 20 ₁ in the state FIG. 10 (a) is a Z-shaped as shown in FIG. 10 (b), is bent relative to the dashed line T. Incidentally, it bent Similarly for the wire _{20 2-20 11.}

  Next, preliminary soldering is performed on the tapered surfaces Q and R of each wire. This preliminary soldering step corresponds to an example of a pretreatment step of the present invention, and soldering corresponds to an example of the brazing of the present invention. Examples of the brazing include silver brazing, gold brazing, or copper brazing. May be used.

Next, as shown in FIG. 11, the wires 20 _{1 to} 20 ₁₂ and 21 _{1 to} 21 ₁₂ are stacked in a U-shape and arranged. The wire rods 20 _{1 to} 20 ₁₂ and 21 _{1 to} 21 ₁₂ are arranged so that the tip end QE (see FIG. 9) of the taper-shaped surface Q is in contact with the step T of the taper-shaped surface R. Here, the wire rod 21 ₁ , member 23 of the _one U-shaped by arranging a combination of wire 20 ₁ and wire rod 21 ₁ is formed. Similarly wire 21 _2, wires 20 ₂ and the wire 21 ₂ member 23 ₂ of one U-shaped by arranging in combination is formed, consisting of a total of 12 pieces of U-shaped members ₂₃ 1 _{to 23 12} Is formed. The step of arranging the wires 20 _{1 to} 20 ₁₂ and 21 _{1 to} 21 ₁₂ in this way so that a plurality of U-shaped members are stacked corresponds to an example of the first arrangement step of the present invention. . The U-shape of the present embodiment corresponds to an example of a quadrangular shape lacking one side of the present invention. The other end of the present invention corresponds to the tip QE of the present embodiment.

  And the connection part (part where taper-shaped surface R and Q overlap) of the some wire 20 and 21 is pinched | interposed and fixed as shown by the arrow A (refer FIG. 11). In addition, the code | symbol of the coil 10 of FIG. 3 corresponding to the code | symbol is described in the parenthesis next to the code | symbol of FIG.

  FIG. 12 shows a state in which a plurality of wires 20 and 21 are sandwiched between jigs 22 and fixed in a U-shape.

Next, as shown in FIG. 13, U-shaped members 23 ₁ to 23 ₁₂ are inserted into the slot 3 from below the stator iron core 2 (see the arrow B direction). FIG. 14A is an enlarged view showing one open side of the members 23 ₁ to 23 ₁₂ inserted into the slot 3. Thus, the process of inserting the U-shaped members 23 ₁ to 23 ₁ into the slot 3 corresponds to an example of the insertion process of the present invention.

Next, from the state shown in FIG. 14A, the wire rods 24 _{1 to} 24 on the opened sides of the U-shaped members 23 ₁ to 23 ₁₂ mounted in the slot 3 as shown in FIG. 14B. ₁₁ is arranged. This step corresponds to an example of the second arrangement step of the present invention. In the state shown in FIG. 14, each wire is in electrical contact with the tapered surfaces R and Q, but is not mechanically connected.

These wire rods 24 _{1 to} 24 ₁₂ correspond to the upper sides 17 _{1 to} 17 ₁₁ of the coil 10 shown in FIG. As shown in FIG. 14B, the wire 24 ₁ is disposed so as to connect the member 23 ₁ and the member 23 ₂ , and the wire 24 ₂ is disposed so as to connect the member 23 ₁ and the member 23 ₂ . Similarly, the wires 24 ₃ to 24 ₁₁ are arranged. Thus, the wire 24 _1, because it is arranged so as to connect between the members of the U-shape, so that compared to the length and wire 20 ₁ to form a lower side 15 ₁ shown in FIG. 3 becomes longer It is cut from the flat wire 25.

Further, the two tapered surfaces R of the member 23 ₁ of the U-shaped, wire rod 24 ₁ is arranged on one, the other becomes an open end, corresponding to the end portion 11 shown in FIG. On the other hand, of the two tapered surfaces R of the member 23 ₁₂ U-shaped, wire rod 24 ₁₁ is arranged on one, the other becomes an open end, corresponding to the end portion 12 shown in FIG. 14 (a) and 14 (b), only _one U-shaped member 23 ₁ to 23 ₁₂ is arranged on the stator iron core 2 for the sake of explanation, but it is shown in FIG. 14 (c). Thus, 18 U-shaped members 23 ₁ to 23 ₁₂ are arranged.

FIG. 15 is a side view of the state of FIG. As shown in FIG. 15, the wire rods 24 _{1 to} 24 ₁₁ are arranged so that the tip end QE of the tapered surface Q contacts the step T. After the wire _{24 1-24 11} thus becomes the top side _{17 1-17 11} is disposed, the portion (see FIG. 13 (b) arrow C) of the upper side of the left and right ends by the jig 22 shown in FIG. 11 is sandwiched Fixed. Note that sites not place the wire 24 _{1-24 11} shown in FIG. 14 (a) is equivalent to an example of the opened portion after lamination of the present invention.

Next, a current flows between the end 11 and the end 12 shown in FIG. Here, each of the wire rods 20 _{1 to} 20 ₁₂ , 21 _{1 to} 21 _12, and 24 _{1 to} 24 ₁₁ is electrically connected to the taper-shaped surfaces Q and R through the solder by being sandwiched by the jig 22. However, since it is only in contact with each other, the resistance value at the contact portion between the wires becomes high.

  For this reason, when a current is passed as described above, heat is generated in a portion having a high resistance value, the applied solder is melted, and the wires are electrically and mechanically connected. Thus, the process of electrically connecting each wire corresponds to an example of the connection process of the present invention. Further, depending on the amount of solder to be applied, the taper-shaped surfaces R and Q, which are examples of the connection surface of the present invention, may be electrically connected over the entire surface, or may be partially electrically connected. There is also. An example of the conductive member of the present invention corresponds to solder or the like.

After energization as described above, the jig 22 is removed. Subsequently, an insulation process is performed on the cut surface of each wire (see the hatched portion Z in FIG. 14B). Further, for example, it corresponds to the surfaces on both ends 20 ₁ b, 21 ₁ b, 24 ₁ b side shown in FIG. This insulation treatment may be performed simultaneously with the varnish treatment or may be performed separately. In addition, since the varnish treatment is a treatment in which the stator 1 is immersed in an insulating varnish such as epoxy, urethane, or polyester, the number of steps can be reduced by performing the insulation treatment simultaneously with the varnish treatment. Furthermore, since a plurality of pieces can be insulated at a time, it is suitable for automation.

  The coil 10 is manufactured through the above processes.

  Thus, in this Embodiment, since the coil 10 is manufactured using a wire, compared with the case where a coil is produced by press-working the conventional copper plate, it is possible to save waste of material. I can do it.

  Further, the pre-solder applied to the surfaces of the tapered surfaces R and Q may be melted by irradiating a laser in addition to the energization or applying hot air. However, since it may be difficult to perform laser irradiation or hot air may not reach the connection location (for example, the sixth turn) near the center of the coil 10, it is more preferable to melt the coil 10 by energization.

  Further, in the coil 10 of the present embodiment, each corner can be made vertical as compared with the case where a single rectangular wire 5 is wound edgewise and wound, so that the height can be reduced. It becomes.

In the present embodiment, the coil 10 is configured such that both ends of the wire rods 20 _{1 to} 20 ₁₂ , the wire rods 21 _{1 to} 21 ₁₂ and the wire rods 24 _{1 to} 24 ₁₁ are cut into a tapered shape, and the tapered shapes are overlapped. However, the present invention is not limited to this configuration. For example, the coil may be configured using a wire rod cut as shown in FIGS. 16 (a) and 16 (b). FIG. 16A is a diagram illustrating a modification of the present embodiment, and corresponds to FIG. 7 describing the present embodiment. FIG. 16B is a diagram in which the sides shown in FIG. 16A are connected.

16 (a) and 16 (b), both ends of the upper side 17 ₁ ′, the left side 14 ₁ ′, the lower side 15 ₁ ′, and the right side 16 ₁ ′ are inclined by about 45 degrees with respect to the longitudinal direction, The coil is cut by cutting in a direction perpendicular to the plane, and the cut surfaces S of each side are connected to face each other. This cut surface S, will be described with reference to FIG. 9, the top surface _{20 1 a, 24 1 a,} 21 1 a and the direction perpendicular to the flat wire 5 ₁ cutting, the cut surface S insulating film are peeled off A trapezoidal shape as shown in FIG. 16 is formed.

Further, each rectangular wire is cut so that the angle formed by the cut surface and the one side surface 20 ₁ e is approximately 45 degrees. A cut surface S shown in FIGS. 16A and 16B corresponds to an example of a predetermined portion of the present invention. In addition, in FIG. 16, this 45 degree | times is shown and one end is shown as 17 < ₂ >'e. Further, the cut surface may be formed so as to be perpendicular to the end 17 _{2 ′} e. However, since a larger area of the portion connecting the wire is advantageous in terms of mechanical strength, as shown in FIG. It is more preferable that the cut surface is formed at substantially 45 degrees. This substantially 45 degrees refers to a range that is regarded as 45 degrees for social reasons. Thus, as a wire which comprises a coil by arrange | positioning cut surfaces S facing each other, you may use not only the above-mentioned rectangular wire but a round wire. Further, as shown in FIG. 16C, a plurality of round wires 30 arranged in parallel in the width direction may be used instead of the rectangular wires.

In the present embodiment, both ends of the wire rods 20 _{1 to} 20 ₁₂ , the wire rods 24 _{1 to} 24 ₁₂ and the wire rods 21 _{1 to} 21 ₁₂ are cut so as to form the tapered surfaces R and Q. Only the insulating film on the surface may be peeled off without shaving. However, if only the insulating film on the surface is peeled and the coil is made by overlapping the peeled portions, the thickness of the connecting portion of the wire becomes larger than the thickness of the wire, so the space factor when mounted in the slot 3 decreases. Will do. Therefore, it is more preferable that the connecting portion of the wire is formed in a tapered shape. Further, although the step T described in this embodiment need not be formed, it is preferable to form the step T because it is easy to position the wire when placing the wire.

In the present embodiment, the connection of each wire with solder has been described. However, the wires may be bonded using a conductive adhesive or may be connected using a thermosetting adhesive. When the conductive adhesive is used, when the wires 24 _{1 to} 24 ₁₁ are arranged in the state shown in FIG. 13B, the wires are electrically connected. This conductive adhesive is, for example, a combination of an epoxy resin and Ag (silver), and is used in the same manner as a normal adhesive.

  In the present embodiment, as shown in FIG. 8, the same coil 10 is mounted on the stator iron core 2, but for example, the wire rods of the coils connected adjacently by connection between the U phases are spread. The turning direction may be the opposite direction. In this case, the ends 11 and 12 of the coils connected adjacent to each other between the U phases are connected by the connection 18. The same applies between the V phase and the W phase. The coil whose winding direction is the opposite direction is described in the present embodiment in which the wire is connected clockwise from the end portion 11 toward the end portion 12 when viewed from the outside of the stator 1. The coil 10 is configured by connecting a wire rod counterclockwise to the coil 10.

  The polygonal shape of the present invention corresponds to, for example, the rectangular coil 10 of the present embodiment, but is not limited to this shape, and may be a parallelogram shape or a trapezoidal shape, and is not limited to a quadrangular shape. It may be a pentagon or a hexagon.

In addition, according to the present invention, “the rectangular wire forming the member arranged on the other side is wider than the rectangular wire forming the member arranged on one side with respect to the stacking direction. the "plurality of the members are arranged such that smaller, for example, in the present embodiment, as shown in FIG. 5, in turn narrower 5w into the flat wire 5 ₁ to 5 _12, thickness 5h is This is equivalent to being thicker.

Thus coil 10 of the present embodiment, different from the thickness and width for each circumferential, and cross-sectional area the same flat wire 5 ₁ to 5 _12, differ only thickness for each circumferential cross-sectional area different from the flat wire 25 _to 253 ₁₂ are formed using cross-sectional area of the same, it may be used one flat wire whose width and thickness changes continuously. Further, in this embodiment, for example, the upper side 17 ₁ and the lower side 15 ₁ constituting the first lap is formed by the flat wire _{5 1,} the left side 14 ₁ and the right side 16 ₁ is formed by a rectangular wire 25 ₁ but vertical and horizontal four sides may be formed by the same rectangular wire 5 _1.

  Furthermore, the coil may be created using only rectangular wires having the same thickness and width. However, when a rectangular wire having a different width and thickness is used as shown in FIG. It is more preferable because the volume factor can be improved.

Moreover, the length which cut _| disconnects the flat wire _51-11 and the flat wire _251-112 can be suitably changed with the shape of a stator iron core.

(Embodiment 3)
The coil according to the third embodiment of the present invention will be described below. FIG. 17 is a front perspective view of the coil according to the third embodiment. As shown in FIG. 17, the coil of the third embodiment has the same basic configuration as the coil of the first embodiment, but the left side, the lower side, and the right side are formed by bending a single rectangular wire. The difference is that the same rectangular wire is used. Therefore, this difference will be mainly described. The front view is a state in which the coil 60 is viewed from the position on the outer peripheral side of the stator 1 on the assumption that the coil 60 is mounted on the stator iron core 2 as in the first embodiment.

  18 (a) is a front view of the coil 60 of the present embodiment, FIG. 18 (b) is a top view of the coil 60, FIG. 18 (c) is a right side view of the coil 60, and FIG. 18 (d). Is a left side view of the coil 60, FIG. 18E is a rear view of the coil 60, and FIG. 18F is a bottom view of the coil 60.

  As shown in FIGS. 18A to 18E, unlike the first embodiment, the coil 60 is configured by a U-shaped member 70 in which a single rectangular wire is curved on the left side, the lower side, and the right side. Yes. Therefore, the coil 60 according to the third embodiment includes 12 U-shaped members 70 and 11 upper sides arranged at the opened portions so as to continuously connect the U-shaped members. 71. The U-shaped member 70 is curved and formed so that the laminated surface 70a is substantially on the same plane. The upper side 71 is formed by a rectangular wire having the same width and thickness as the rectangular wire forming the U-shaped member 70.

The U-shaped members 70 ₁ to 70 ₁₂ and the upper sides 71 _{1 to} 71 ₁₁ are distinguished in order to distinguish the U-shaped member 70 and the upper side 71 in the first to twelfth rounds from the front side. And subscripts in order. When the U-shaped member 70 and the upper side 71 are simply indicated, the entire first to twelfth rounds are shown.

  As shown in FIGS. 17 and 18A and 18C, the coil 60 has one end 61 on the front side and the other end 62 on the back side.

End 61 is positioned at the upper end portion of the U-shaped member 70 ₁ of the left side 70 1 _L when viewed from the front.
This upper end of the U-shaped member 70 ₁ of the right side 70 ₁ R, the upper side 71 ₁ of the right end are connected. 1 lap coil 60 is formed by a member 70 ₁ and the upper side 71 ₁ of the U-shape.

Then, the left end of the upper side 71 _1, the upper end of the second week of U-shaped member 70 ₂ of the left side 70 ₂ L is connected. In this way, the first to eleventh rounds are formed. Then, are member _{70 12} is connected to lap 12 of the U-shaped right end of the lap 11 of the upper side _{71 11,} the upper end of the right side _{70 12} R of U-shaped member _{70 12} is turned end 62 Yes. For this reason, the upper side is not connected to the twelfth turn. . An example of the plurality of coil materials for transition according to the present invention corresponds to the upper sides 71 _{1 to} 71 ₁₁ .

Further, the upper side _{71 1-71 12,} as in the first embodiment, the step at both ends for connecting member 70 ₁ of the first round U-shaped and the second round of the U-shaped member 70 ₂ It is bent so that

In the third embodiment, the U-shaped members 70 ₁ to 70 ₁₂ are members having the same shape formed using the same rectangular wire.

  Next, a connection structure between the upper side 71 and the U-shaped member 70 will be described.

FIG. 19 is a diagram illustrating a state where the connection between the U-shaped member 701 and the upper side 71 _{1 in} the _first round is released. As shown in FIG. 19, the upper end ₇₀ 1 d, 70 ₁ e portion of the member 70 ₁ of the U-shape, tapered surface R so that the thickness 70 ₁ h becomes thinner upward is formed. Further, a step T is provided below both tapered surfaces R.

On the other hand, a tapered surface Q is formed at the right end 71 ₁ R of the upper side 71 ₁ so that the thickness 71 ₁ h becomes thinner in the downward direction.

A tapered surface R of the upper end 70 ₁ e of the member 70 ₁ of the right side 70 ₁ R side of the U-shape, tapered surface Q of the upper side 71 ₁ of the right end 71a overlaps, in FIG. 6 (a) ~ (c) Connected as shown. 6A to 6C, the tip QE of the tapered surface Q is in contact with the step T also in the second embodiment.

An example of the coil material of the present invention corresponds to U-shaped members 70 ₁ to 70 ₁₂ and upper sides 71 _{1 to} 71 ₁₁ . An example of the open end of the coil material of the present invention corresponds to the upper ends 70 ₁ d and 70 ₁ e in the U-shaped member in FIG. 19, and the upper end 71 ₁ has a right end 71 ₁ R and a left end 71 ₁ L. It corresponds to.

(Embodiment 4)
Below, the manufacturing method of the coil in Embodiment 4 concerning this invention is demonstrated. This manufacturing method is a method for manufacturing the coil 60 attached to the stator core 2.

  First, as shown in FIG. 20A, a rectangular wire 75 having a rectangular cross-sectional shape is cut into a wire 76 for the upper side 71 and a wire 77 for the U-shaped member 70 shown in FIG. The The process of cutting the flat wire 75 in this way corresponds to an example of the cutting process of the present invention.

  Here, the thickness of the wire 76 is 76h, the upper surface is 76a, both end portions in the longitudinal direction are 76b, and the width is 76w. The side surface in the width 76w direction is 76e. Similarly to the wire rod 76, the wire rod 77 has a thickness of 77h, an upper surface of 77a, both end portions of 77b, a width of 77w, and a side surface in the width 77w direction of 77e.

  Next, as shown in FIG. 20B, the insulating films on both ends in the longitudinal direction of the wire rod 76 and the wire rod 77 are peeled off as in the second embodiment. In this peeling step, the both ends of the wire 76 are scraped on the upper surface 76a side so as to form a tapered surface Q such that the thickness 76h gradually decreases from one side surface 76e to the other side surface 76e. Thus, the process of cutting the both ends 76b of the wire 76 so as to form the tapered surface Q corresponds to the cutting B process of the present invention.

  In addition, as for both end portions 77b of the wire 77, the upper surface 77a side is cut so as to form a tapered surface R in which the thickness 77h gradually decreases toward the end. The process of cutting both end portions 77b of the wire 77 so as to form the tapered surface R in this way corresponds to an example of the cutting A process of the present invention. At the same time, a step T is formed at the end of the taper-shaped surface R on the center side of the wire 77. This step corresponds to an example of the step forming step of the present invention.

  In this way, by cutting the wires 76 and 77, the insulating films of the tapered surfaces Q and R and the step T are peeled off. Further, the step of cutting the wire on the tapered surfaces Q and R corresponds to an example of the peeling step of the present invention. An example of the predetermined member of the present invention corresponds to the vicinity of both end portions 77 b of the wire 77 or the vicinity of both end portions 76 b of the wire 76. An example of the contact surface of the present invention corresponds to the tapered surfaces Q and R of the present embodiment. The other end of the present invention corresponds to the tip QE of the present embodiment.

Subsequently, as shown in FIG. 20C, the wire rod 76 is bent in the same manner as the wire rod 201 of the _first embodiment. The bent wires 76 corresponds to the upper side 71 ₁ (see Figure 10 (b)).

On the other hand, as shown in FIG. 20 (c), the wire 77 is bent so that the upper surface 76a is positioned on the same plane, one example of a bending process of the member 70 ₁ of the U-shape is created (the present invention Equivalent to). The upper surface 76a corresponds to an example of the laminated surface of the present invention.

In the same manner as described above, the flat wire 75 is further cut and both ends are cut repeatedly to form U-shaped members 70 ₂ to 70 ₁₂ and upper sides 71 _{2 to} 71 ₁₁ .

  Subsequently, as in the second embodiment, preliminary soldering is performed on the tapered surfaces R and Q of each wire.

Then, instead of the U-shaped members 23 ₁ to 23 ₁₂ described in the second embodiment, a plurality of U-shaped members 70 ₁ to 70 ₁₂ of the present embodiment are stacked and sandwiched by the jig 22. This is inserted into the slot 3 (see FIG. 14A). This step corresponds to an example of the first arrangement step of the present invention.

Subsequently, the bent wire 76 (upper sides 71 _{1 to} 71 ₁₁ ) is disposed in the opened portions of the U-shaped members 70 ₁ to 70 ₁₂ (see FIG. 14B). This step corresponds to an example of the second arrangement step of the present invention. And by supplying with electricity, solder will melt and electrical connection will be performed. This process corresponds to an example of the connection process of the present invention.

  Next, as in the first embodiment, the insulation treatment of the cut surface Z of the wire (see FIGS. 20A and 20B) is performed simultaneously with or separately from the varnish treatment to form an insulation film.

  The coil 60 is created through the above steps.

  As described above, in the fourth embodiment, since the coil 10 is manufactured using the wire material, waste of material is reduced as compared with the case where the coil is manufactured by pressing a conventional copper plate. I can do it.

  Further, in the coil 60 of the present embodiment, compared with the case where one flat wire 5 is wound edgewise and wound, at least two corners on the upper side can be made vertical, so that the height is reduced. It becomes possible to plan.

  Although the U-shaped member 70 is described as an example of the predetermined member of the present invention, the U-shaped member 70 is not limited to the U-shape, and may be a trapezoidal shape having no upper side.

  Also in the third embodiment, as described with reference to FIG. 16, the coil 76 is created by arranging the cut surfaces (surfaces on both end portions 76 b and 77 b side) of the wire 76 and the wire 77 facing each other. Also good.

  Further, as in the first and second embodiments, in the coil 60 shown in FIG. 17, rectangular wires having different thicknesses and widths may be used for each turn. In this case, as shown in FIG. 3, it is preferable that each rectangular wire is a rectangular wire having a width that decreases in the depth direction, a thickness that increases, and a cross-sectional area that is the same.

  In the present embodiment, the same flat wire 75 is used for the upper side 71 and the U-shaped member 70, but different flat wires may be used for the upper side and the U-shaped member.

  In the fourth embodiment, one flat wire 75 is cut and then bent into a U shape, but may be cut after being bent into a U shape.

  Further, the tapered shapes Q, R and the step T are formed before being bent into the U shape, but the tapered shapes Q, R and the step T may be formed after being bent into the U shape.

(Embodiment 5)
The coil according to the fifth embodiment of the present invention will be described below, and an example of the method for manufacturing the coil of the present invention will also be described. In the coil of the fifth embodiment, a concave portion 80 is formed on one of the tapered surfaces R and Q of the coils 10 and 60 described in the first to fourth embodiments.

  Hereinafter, the coil of the fifth embodiment will be described using the first embodiment.

FIG. 21 is a diagram illustrating a state in which the concave portion 80 is formed on the tapered surface R at the upper end of the right side 161 of the _first embodiment. This FIG. 21 is a figure corresponding to FIG.6 (b). Figure 22 (a) is a plan view of the right side 16 _1, FIG. 22 (b) is a sectional view of the right side 16 _1. As shown in FIG. 21 and FIGS. 22 (s) and 22 (b), the recess 80 has a circular shape in plan view and is formed to have a semi-elliptical cross section. Such a recess 80 is formed by pressing. Thus, the process of forming the recessed part 80 corresponds to an example of the recessed part forming process of the present invention. In addition, the surface of the tapered surface R excluding the inside of the recess 80 is subjected to insulation treatment.

As a method of insulating processing performed, as shown in FIG. 23, the X part of the plan to form a recess 80 of the wire 21 _first tapered surface R, the wire 20 _1, 24 ₁ of tapered surface Q, wire A masking material is applied to the Y portion that faces the concave portion 80 when the is connected. The X part and Y part correspond to the part with dots in FIG.

Next, the surfaces of the wires 20 ₁ , 21 ₁ , 24 ₁ other than the X part and the Y part are insulated by immersing each wire 20, 21, 24 in an insulating material (such as epoxy resin) and washing away the masking material. Is done. In addition, the cut surface Z portion is also insulated by this process, so that the insulation treatment of the cut surface Z after energization heating is not required (see FIG. 14B). This process corresponds to an example of the insulation process of the present invention. An example of one contact surface of the present invention corresponds to the tapered surface R of the present embodiment, and an example of the periphery of the concave portion of the present invention is other than the X portion of the tapered surface R of the present embodiment. Corresponds to the part. An example of the other contact surface of the present invention corresponds to the tapered surface Q of the present embodiment, and an example of a portion facing the recess of the present invention is a Y portion of the tapered surface Q of the present embodiment. It corresponds to.

  When the insulation treatment is performed by immersing the wire in this manner, the process can be automated, which is advantageous in terms of cost when producing in large quantities.

Next, preliminary solder is applied to the wires 20 ₁ , 21 ₁ , 24 ₁ , but when the recess 80 is formed as shown in FIG. 21, a wax having viscosity is applied to the inside of the recess 80. . As an example of this wax, cream solder can be used. The same applies to the other wire rods 20 _{2 to} 20 ₁₂ , the wire rods 24 _{1 to} 24 ₁₁ , and the wire rods 21 _{2 to} 21 ₁₂ .

A state in which cream solder is applied to the recess 80 is shown in a side view of FIG. Incidentally, in FIG. 24, right side 16 ₁ is shown as an example. As shown in FIG. 24, the cream solder 81 is applied in the recess 80 so as to protrude from the tapered surface R. The amount of the cream solder 81 applied is adjusted to be the same as or slightly smaller than the volume of the recess 80.

Thereafter, as described in the first embodiment, by arranging each wire, the cream solder 81 is brought into close contact with the opposing tapered surface R and is heated by energization, whereby the cream solder 81 is melted and the wire rods are separated. (For example, the right side 16 ₁ and the upper side 17 ₁ ) are electrically connected.

  As described above, by forming a recess in one of the tapered surfaces R and Q and adjusting the amount of the conductive member applied to the recess, when the tapered surface R and the tapered surface Q are overlapped, It is possible to suppress the connection metal from protruding to the surroundings. In addition, since the connecting metal does not protrude, the treatment for insulating the cut surface Z (see FIG. 14B) is facilitated. Furthermore, since the amount of protrusion can be suppressed, the amount of expensive conductive members used can be minimized, which is advantageous in terms of cost.

  In the first to fourth embodiments, as described with reference to FIG. 14B, an insulation treatment is performed to form an insulating film on the cut surface Z after the energization heating is performed. Similarly, in the state of the wire rods 20, 21, and 24 in which the tapered surfaces Q and R and the step T are formed, the insulation treatment may be performed first. In this case, as shown in FIG. 25, a masking material is applied to the surfaces of taper-shaped surfaces Q and R and step T (parts to which dots are attached). Thereafter, each of the wires 20, 21, and 24 is immersed in an insulating material (such as an epoxy resin). By soaking, the Z portion indicated by hatching is insulated. Thereafter, by washing away the masking material, a wire in a state where only the surfaces of the tapered surfaces Q and R and the step T are not insulated is created.

  Further, the recess 80 is not limited to the shape of the present embodiment, and it is sufficient that the recess 80 is recessed from the tapered surface R. Moreover, you may form a recessed part in the cut surface S demonstrated in Fig.16 (a) (b).

In the above-described embodiment, the rectangular wires _{51 to 12} and the rectangular wires 25 to ₁₂ are used as an example of the coil material of the present invention, but a round wire or the like may be used. As shown in FIG. 26A, a round wire 30 may be used instead of the flat wire. In this case, an example of the laminated surface of the present invention is a plane 31 perpendicular to a line connecting the centers between the round lines 30. Further, as shown in FIG. 26B, a plurality of round wires 30 arranged in the length direction may be used as an example of the wire of the present invention. In this case, an example of the laminated surface of the present invention corresponds to a surface 32 indicated by a dotted line.

Further, as an example of the flat wire of the present invention, as shown in FIG. 26 (c), may be used a wire 50 ₁ of repeated three rectangular wire 5 ₁ in the thickness direction.

In the above-described embodiment, each wire is arranged so that the tip QE of the tapered surface Q contacts the step T of the tapered surface R. However, the step T is not provided and the tip QE is not provided. May not contact. In the first embodiment, the width 25 ₁ w and the length 5 ₁ s are substantially the same in FIG. 6B. For example, the width 25 ₁ w has a length of 5 It may be shorter than ₁ s, in short, it is only necessary that the sides forming the coil are connected to each other.

  Moreover, in Embodiments 1-5, the wire which is an example of the coil raw material of this invention is created by cut | disconnecting one flat wire in the orthogonal | vertical direction with respect to the longitudinal direction as shown, for example in FIG. However, a wire may be created by cutting a plate-like member into a strip shape.

  Moreover, in the coils of the first to fifth embodiments, only the top 11 is provided, but 12 may be provided.

  In the above-described embodiment, the stator coil has been described. However, the stator coil may be applied to each phase coil for a rotor and a linear motor, or may be used as a transformer. In this embodiment, the upper side portion is disposed after being inserted into the stator iron core 2. However, for example, in the case of a disassembleable stator iron core, the coil 10 is first assembled and then assembled to the stator iron core. May be.

  The coil and the coil manufacturing method of the present invention have an effect that waste of material can be further reduced, and are useful as a motor, a generator, an armature, and the like.

The perspective view of the stator in Embodiment 1 concerning this invention (A) The top view of the stator in Embodiment 1 concerning this invention, (b) The side view of the stator in Embodiment 1 concerning this invention The perspective view of the coil in Embodiment 1 concerning this invention. (A) Front view of coil in embodiment 1 according to the present invention, (b) Plan view of coil in embodiment 1 according to the present invention, (c) Right side surface of coil in embodiment 1 according to the present invention FIG. 4D is a left side view of the coil according to the first embodiment of the present invention, FIG. 3E is a rear view of the coil according to the first embodiment of the present invention, and FIG. 4F is a coil according to the first embodiment of the present invention. Bottom view of Sectional view between XX 'in FIG. Enlarged view of Fig. 4 (b) (A)-(c) The figure for demonstrating the connection of each edge | side of the coil of Embodiment 1 concerning this invention. The figure which shows the state which isolate | separated each edge | side in the 1st round of the coil of Embodiment 1 concerning this invention. 1 is a schematic plan view of a stator according to a first embodiment of the present invention. The figure which shows the state which cut | disconnected the rectangular wire used for the manufacturing method of the coil in Embodiment 2 concerning this invention, and created the wire The figure which shows the state which formed the taper shape in the flat wire used for the manufacturing method of the coil in Embodiment 2 concerning this invention. (A) (b) The figure for demonstrating bending of the flat wire used for the manufacturing method of the coil in Embodiment 2 concerning this invention. The figure for demonstrating the state which laminated | stacked and arrange | positioned the U-shaped member in the manufacturing method of the coil in Embodiment 2 concerning this invention. The figure for demonstrating the state which fixed the U-shaped member laminated | stacked in the manufacturing method of the coil in Embodiment 2 concerning this invention with the jig | tool. The figure for demonstrating the state which mounts the laminated U-shaped member fixed with the jig | tool in the coil manufacturing method in Embodiment 2 concerning this invention to a stator. The figure for demonstrating the process of arrange | positioning a wire to the site | part by which the U-shaped member was open | released in the manufacturing method of the coil in Embodiment 2 concerning this invention. The figure for demonstrating the process of arrange | positioning a wire to the site | part by which the U-shaped member was open | released in the manufacturing method of the coil in Embodiment 2 concerning this invention. The figure for demonstrating the process of arrange | positioning a wire to the site | part by which the U-shaped member was open | released in the manufacturing method of the coil in Embodiment 2 concerning this invention. Side view for demonstrating the state which has arrange | positioned the wire in the site | part by which the U-shaped member was open | released in the manufacturing method of the coil in Embodiment 2 concerning this invention. (A)-(c) The figure for demonstrating the coil of the modification of this invention Front perspective view of a coil according to a third embodiment of the present invention. (A) Front view of coil in embodiment 3 according to the present invention, (b) Plan view of coil in embodiment 3 according to the present invention, (c) Right side surface of coil in embodiment 3 according to the present invention FIG. 4D is a left side view of the coil according to the third embodiment of the present invention. FIG. 5E is a rear view of the coil according to the third embodiment of the present invention. FIG. Bottom view of The figure which shows the state which isolate | separated each edge | side in the 1st round of the coil in Embodiment 3 concerning this invention. (A)-(c) The figure for demonstrating the manufacturing method of the coil in Embodiment 4 concerning this invention. The perspective view which isolate | separated the upper side and the right side in order to demonstrate the recessed part of the coil in Embodiment 5 concerning this invention (A) The top view of the wire which comprises the right side for demonstrating the recessed part of the coil in Embodiment 5 concerning this invention, (b) Sectional drawing between AA 'of (a). The figure for demonstrating the insulation process in the manufacturing method of the coil of Embodiment 5 concerning this invention. The figure for demonstrating the process of apply | coating the electroconductive member in the manufacturing method of the coil of Embodiment 5 concerning this invention. The figure for demonstrating the modification of the insulation process in the manufacturing method of the coil of Embodiment 2 and 4 concerning this invention (A)-(c) The figure for demonstrating the coil of the modification of this invention The figure which shows the copper plate used for the manufacturing method of the conventional coil (A)-(c) The figure for demonstrating the manufacturing process of the conventional coil A perspective view of a conventional coil (A)-(c) The figure for demonstrating mounting | wearing with the conventional coil to a stator iron core

Explanation of symbols

1 stator 2 stator iron core 3 slot 4 the tooth 10 coils 11 and 12 end 14 _{1-14 12} left 15 _{1-15 12} lower side 16 ₁ to 16 ₁₂ right 17 _{1-17 11} upper 18 connecting 20 ₁ to 20 ₁₂ wire rod 21 ₁ to 21 _12-wire material 22 jig

Claims (30)

A member in which the cut coil material is arranged corresponding to each side of the polygonal shape with at least one side open, or a member formed by bending one coil material into a predetermined shape with at least one side open is the above-mentioned opening A first arrangement step of stacking a plurality of aligned one sides;
A second arrangement step of arranging a plurality of coil materials so that the laminated members are continuously connected to the opened portion after the lamination;
A connection step in which all the coil materials arranged in a continuous manner are connected so as to be continuously electrically connected at all or part of the contact surfaces where both ends of each of the coil materials contact each other. The manufacturing method of a coil.   The member formed by bending the one coil material into a predetermined shape with at least one side open is a member obtained by bending a rectangular wire into a U shape, and the laminated surface thereof is substantially flush with each other. The coil manufacturing method according to claim 1, wherein the coil is bent. A cutting step of cutting one or a plurality of types of rectangular wires to create a plurality of the coil materials;
A peeling step of peeling the insulating film at a predetermined portion of each of the both ends of the plurality of coil materials to form the contact surface;
The coil manufacturing method according to claim 1, wherein the second arrangement step is a step of arranging the plurality of coil materials so that the contact surfaces face each other.   The method for manufacturing a coil according to claim 3, wherein the predetermined part is a part on the laminated surface side of the both ends of the coil material. The member is a member arranged in a polygonal shape with at least one side open, with the coil material as one side,
The polygonal shape in which at least one side is open is a quadrangular shape having two pairs of opposing sides as a first set and a second set, with one side of the second set missing,
The peeling step includes
Preparing the coil material corresponding to each side of the square shape,
The thickness of the predetermined portion of the coil material arranged as a pair of sides of the first set in the quadrangular shape is reduced from the center side to the end side in the longitudinal direction of the coil material. A first cutting step of cutting the vicinity of both ends of one surface of each coil material of one set to form the contact surface;
The thickness of the predetermined part of the coil material arranged as a pair of sides of the second set in the quadrangular shape is reduced from one end to the other end along the width direction of the coil material. A second cutting step of cutting the vicinity of both ends of one surface of the coil material of each of the second set to form the contact surface;
In the first arrangement step and the second arrangement step, the contact surfaces in the pair of sides of the first set and the contact surfaces in the pair of sides of the second set are opposed to each other. The method for manufacturing a coil according to claim 4, wherein the coil material is a step of arranging the coil material. The first cutting step includes
A step forming step for forming a step on the center side of the predetermined portion of the coil material arranged as a pair of sides of the first set;
In the first arrangement step and the second arrangement step, the other end along the width direction of the predetermined portion of the coil material arranged as a pair of sides of the second set is the first arrangement step. The coil manufacturing method according to claim 5, wherein the coil material is a step of arranging the plurality of coil materials so as to be in contact with the steps of the pair of coil materials. After the first arrangement step, the method further includes an insertion step of inserting a pair of sides of the first set of the quadrangular members into slots of the stator or the rotor,
The method for manufacturing a coil according to claim 5, wherein the second arranging step is performed after the inserting step. The cutting step includes a step of cutting a plurality of types of rectangular wires having the same cross-sectional area and different thicknesses and widths, and preparing a plurality of types of the coil material used for the pair of sides of the first set,
The first arrangement step includes
The coil material cut from one type of the rectangular wire is disposed so as to form a pair of sides of the first set of one of the quadrangular members,
In the first set, a plurality of the rectangular wires arranged on the other side are smaller than the rectangular wires arranged on one side with respect to the stacking direction so that the width is smaller. The coil manufacturing method according to claim 5, wherein the coil material is disposed. The member formed by bending the one coil material into a predetermined shape with at least one side open is a member obtained by bending a flat wire into a U shape,
Further comprising a bending step of bending the coil material into a U-shape so that the laminated surfaces are substantially flush with each other,
The peeling step includes
A step of preparing the coil material for forming the U-shaped member, and the coil material to be disposed in the opened part,
Near both ends of one surface of the coil material such that the thickness of the predetermined portion of the coil material forming the U-shaped member becomes thinner from the center side to the end side in the longitudinal direction of the coil material Cutting A step for forming the contact surface, and the thickness of the contact surface portion of the coil material disposed in the opened part is from one end to the other end along the width direction of the coil material. Cutting the vicinity of both ends of one surface of the coil material so as to be thin, and a cutting B step for forming the contact surface,
In the second arrangement step, the contact surface of the coil material formed on the U-shaped member and the contact surface of the coil material disposed on the opened portion are opposed to each other. The method for manufacturing a coil according to claim 4, wherein a plurality of the coil materials are arranged. The cutting A step includes
A step forming step of forming a step on the center side of the predetermined portion of the coil material forming the U-shaped member;
In the second arrangement step, the other end of the coil material arranged in the open part along the width direction in the predetermined part forms the U-shaped member. The coil manufacturing method according to claim 9, which is a step of arranging the plurality of coil materials so as to contact the step. After the first arrangement step, further comprising an insertion step of inserting a pair of opposing sides of the U-shaped member into a slot of the stator or rotor,
The method for manufacturing a coil according to claim 9, wherein the second arrangement step is performed after the insertion step. The cutting step includes a step of cutting a plurality of types of rectangular wires having the same cross-sectional area and different thicknesses and widths, and preparing a plurality of types of the coil material used for the U-shaped member,
The first arrangement step includes
The rectangular wire forming the U-shaped member arranged on the other side is more preferable than the flat wire forming the U-shaped member arranged on the one side with respect to the stacking direction. The method for manufacturing a coil according to claim 9, which is a step of arranging a plurality of the coil materials so that the width is reduced. The second arranging step is a step of arranging the plurality of coil materials so that the contact surfaces face each other.
The manufacturing method of the coil of Claim 1 provided with the recessed part formation process of forming a recessed part in at least one said contact surface among the contact surfaces arrange | positioned facing. A pretreatment step of applying a brazing or a cream-like member containing a conductive material to the inside of the recess,
The connecting step includes
A process of melting all the coil materials by energizing all the coil materials to cause heat generation, and connecting all the coil materials so as to be electrically connected via all or part of the contact surfaces. The method for manufacturing a coil according to claim 13, wherein The pretreatment step includes
The method for manufacturing a coil according to claim 14, wherein the solder or the cream-like member is applied in such a manner that the amount of the wax or the cream-like member is equal to or less than the volume of the recess and protrudes from the recess.   The method of manufacturing a coil according to claim 13, further comprising an insulating film forming step of forming an insulating film around the concave portion of the one contact surface and around a portion of the other contact surface facing the concave portion. . Cutting one or a plurality of types of rectangular wires, and creating a plurality of the coil materials,
The coil manufacturing method according to claim 16, wherein the insulating coating step is a step of simultaneously forming an insulating coating on a cut surface of the coil material. A pretreatment step of preliminarily brazing or applying cream solder containing a conductive material to the contact surface;
The connecting step includes
The step of melting the solder by energizing all the coil materials to generate heat, and connecting all the coil materials so as to be electrically connected via all or part of the contact surface. A manufacturing method of the coil according to 1.   The coil manufacturing method according to claim 14 or 18, wherein a main component of the solder is any one of solder, gold, silver, and copper.   The coil manufacturing method according to claim 14 or 18, wherein the cream-like member is cream solder. Cutting one or a plurality of types of rectangular wires, and creating a plurality of the coil materials,
2. The coil manufacturing method according to claim 1, wherein the first arrangement step is a step of arranging the coil material so that the contact surface faces the cut surface as the contact surface. The connection step is a step of connecting so that both ends of the coil material are electrically connected continuously using a conductive adhesive,
The method for manufacturing a coil according to claim 1, wherein the connecting step is performed during the second arranging step. A laminated member in which a plurality of members arranged in a polygonal shape in which at least one side is open, and a coil material as one side,
A plurality of coil materials for transition arranged in the opened site,
The coil which the both ends of all the said coil element sides are electrically connected continuously. A laminated member in which a plurality of members formed by bending one coil material is laminated so as to have a predetermined shape with at least one side open;
A plurality of coil materials for transition arranged in the opened site,
The coil which the both ends of all the said coil element sides are electrically connected continuously.   The continuous electrical connection means that one open end and the other open end of the stacked coil elements are continuously electrically connected. 24. The coil according to 24.   25. The coil according to claim 24, wherein the member is a member in which a flat wire is bent into a U shape, and the laminated surface is bent so as to be substantially flush with each other. The coil material has a contact surface that comes into contact with the other coil material to electrically connect with the other coil material;
25. The coil according to claim 23 or 24, wherein the coil materials are connected by a conductive member at all or part of the contact surfaces arranged to face each other. The coil material has a contact surface that comes into contact with the other coil material to electrically connect with the other coil material;
The coil according to claim 23 or 24, wherein a concave portion is formed on at least one of the contact surfaces arranged to face each other between the connected coil materials.   29. The coil according to claim 28, wherein an insulating film is formed around the recess of the one contact surface and around a portion of the other contact surface facing the recess.   The coil according to claim 28, wherein the conductive member is present in the recess.

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