JP2008295235A - Production method for armature laminated core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production method for an armature laminated core in which the magnet pole of the armature laminated core is helically wound by flat plate conductors without any manpower, the alignment and connection of the wound plate conductors are performed with high reliability and a coil composed of flat plate conductors are formed. <P>SOLUTION: The end portions of one sides 14, 15 in the width direction of a first and a second flat plate conductors 10, 11 with the same width, which are alternately and continuously arranged in a trapezoidal shape, are connected by bendable connecting parts 16, 17. The other sides 19, 20 of the first and the second flat plate conductors 10, 11 are formed with a group of connecting flat plate conductors 18 having the size corresponding to the length and width of an inner mold 22 respectively determined based on the laminated thickness and width of the magnet pole 21 from flat plate bars. The other side of the group of connecting flat plate conductors 18 is along the magnetic pole 21, the connecting parts 16, 17 are bended in succession, the group of connecting flat plate conductors 18 are helically wound around the magnet pole 21, and the point at which the adjacent first and second flat plate conductors 10, 11 meet is welded or brazed, thereby forming the coil. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

The present invention relates to a method of manufacturing an armature laminated core that can be used for a stator or a rotor of a motor or a generator.

A coil is mounted on a magnetic pole of an armature of a rotating electric machine, for example, a stator laminated core. The coil of the magnetic pole is usually formed by winding a copper wire around this magnetic pole. Recently, as described in Patent Document 1, for example, the coil space factor is increased to reduce copper loss. However, in order to improve the efficiency of the rotating electrical machine or reduce the size, there are some that form a coil with a flat conductor instead of a copper wire.

The flat plate conductor is cut out from a copper plate into an L shape, a U shape, or a B shape with a partly divided portion, and the flat plate conductor is inserted into the slots on both sides across the magnetic pole. It is necessary to electrically connect after aligning the flat conductors made in the above. FIG. 6 shows a method for manufacturing a rotor coil of a rotating electrical machine described in Patent Document 1. A plurality of L-shaped flat conductors 50 are cut out from a conductor plate by pressing as shown in FIG. As shown in FIG. 6B, these are sequentially connected and formed by winding a coil around the magnetic pole in a spiral.

JP 2001-178052 A

However, the method described in Patent Document 1 has a problem that it takes a lot of time to form the coil, resulting in high costs.
Further, skill is required to align the flat conductors, and as shown in FIG. 6 (C), there is a concern that the resistance value may change due to misalignment, interphase insulation defects may occur, or the coil end dimensions may change. There is a problem that.

The present invention has been made in view of such circumstances, and a flat conductor is wound around a magnetic pole of an armature laminated iron core in a spiral shape without requiring labor, and the alignment and connection of the wound flat conductor are reliable. It aims at providing the manufacturing method of the armature laminated core performed with high property.

According to the first aspect of the invention, the armature laminated core manufacturing method according to the first aspect of the invention is an electric machine in which a coil is formed by connecting and winding flat conductors to magnetic poles of an armature laminated core obtained by laminating and integrating core pieces. In the manufacturing method of the child laminated core,
Each of the first and second flat plate conductors having the same width, which are alternately and continuously arranged in a trapezoidal shape, has one end in the width direction of the adjacent first and second flat plate conductors. An articulated flat plate connected by a foldable connecting portion, and the other side of the first and second flat plate conductors has dimensions corresponding to the vertical and horizontal dimensions of the inner mold determined based on the laminated thickness and width of the magnetic poles. A conductor group is formed from a flat strip material,
The other side of the connecting plate conductor group is aligned with the inner mold of the magnetic poles of the armature laminated core, the connecting portion is sequentially bent, and the connecting plate conductor group is spiraled to the magnetic pole via the inner mold. The coil is formed by welding or brazing a portion where the adjacent first and second flat plate conductors abut each other.

In the method of manufacturing an armature laminated core according to the first aspect of the invention, the first and second flat plate conductors having a trapezoidal shape are joined at right angles to each other in the longitudinal direction when bent at the connecting portion. It is preferable to provide possible notches. Thereby, the edge part of the flat conductor made into the same width can be connected reliably.

The armature laminated core manufacturing method according to the second aspect of the invention is an armature laminate in which flat conductors are connected to each other and wound around a magnetic pole of an armature laminated core obtained by laminating and integrating core pieces. In the manufacturing method of the iron core,
The first piece and the second piece have the same width, and the inner sides of the first piece and the second piece have dimensions corresponding to the length and breadth of the inner mold determined based on the lamination thickness and width of the magnetic poles. A plurality of the L-shaped flat conductors, and the ends of one of the flat conductors in the width direction (that is, the outer side) are connected by a foldable connecting portion, and the first piece and the first piece The open-side end of the two pieces is formed from a flat strip member with a connected flat conductor group formed with a notch that can be joined at a right angle when bent at the connecting portion,
The inner side of each flat conductor of the connected flat conductor group is aligned with the magnetic pole of the armature laminated core, the connecting portion is bent sequentially, and the connected flat conductor group is spiraled to the magnetic pole via the inner die. The coil is formed by winding and welding or brazing the place where the adjacent flat conductors meet.

And the manufacturing method of the armature laminated core which concerns on 3rd invention WHEREIN: The armature lamination which connects a flat conductor to the magnetic pole of the armature laminated core formed by laminating | stacking and integrating an iron core piece, and forms a coil In the manufacturing method of the iron core,
From the L-shaped first flat plate conductor, the trapezoidal first flat plate conductor, the L-shaped second flat plate conductor, and the trapezoidal second flat plate conductor, which are sequentially connected at the connecting portion with the same width. The inner sides of the respective flat conductors have the vertical and horizontal dimensions of the inner mold of the magnetic poles sequentially, and when the flat conductors are bent at the connecting portion, the adjacent flat conductors are perpendicular to each other. Forming a connecting flat conductor group having a notch connected to the flat strip material;
The L-shaped first flat conductor, the trapezoidal first flat conductor, the L-shaped second flat conductor, and the trapezoidal second flat conductor of the connected flat conductor group are bent at the connecting portion. On the other hand, the coil is formed by winding the magnetic pole spirally through the inner mold and welding or brazing the locations where the adjacent flat plate conductors abut each other.

In the manufacturing method of the armature laminated core according to the first to third inventions described above, the notch includes a 45-degree inclined side or a convex curved side and a concave curved side that engage with each other in pairs. It is preferable.
In the armature laminated core manufacturing method according to the first to third aspects of the invention, it is preferable that the magnetic pole is provided in each divided yoke of the armature laminated core.

In the method for manufacturing an armature laminated core according to claim 1 or 2, the other side of the connected flat conductor group is placed along the inner side of the magnetic pole of the armature laminated core, the connecting portions are sequentially bent, and the connected flat conductor group Is wound around the magnetic pole in a spiral manner through the inner die, and a coil is formed by welding or brazing the locations where the adjacent first and second flat plate conductors abut each other. The coil of the flat conductor is formed without requiring labor for alignment and without causing positional deviation.
Furthermore, since the flat conductor is formed from a flat strip with a uniform desired width, the material yield can be increased.

In the armature laminated core manufacturing method according to claim 3, the inner side of each flat conductor of the connected flat conductor group is aligned with the magnetic pole of the armature laminated core, the connecting portion is sequentially bent, and the connected flat conductor group is Since the coil is formed by winding or spirally winding the magnetic pole around the magnetic pole through the inner mold and welding or brazing the location where the adjacent flat conductors abut, the first and second pieces of the flat conductor wound spirally are formed. Connection is made without requiring time and labor for positioning with the strip, and a coil made of a flat conductor is formed.

And the manufacturing method of the armature laminated iron core of Claim 4 is the L-shaped 1st flat conductor, the trapezoidal 1st flat conductor, and L-shape which were respectively connected by the connection part sequentially with the same width | variety. The second flat plate conductor and the trapezoidal second flat plate conductor, the inner sides of these flat plate conductors have the vertical and horizontal dimensions of the inner mold of the magnetic poles sequentially, and the flat plate conductors are connected to the connecting portion. When connecting the flat plate conductors, the adjacent flat plate conductor group is formed from a flat strip material and has a notch where the adjacent flat plate conductors are connected at right angles to each other. The first flat plate conductor, the L-shaped second flat plate conductor, and the trapezoidal second flat plate conductor are spirally wound around the magnetic pole through the inner die while bending the connecting portion, and the adjacent flat plate conductors are Since the coil is formed by welding or brazing the abutting part, each flat conductor is Location is not present in succession on the same line in the coiling direction to, is reduced the influence of slight thickness variations due to butt, electromagnetic properties without non-uniform gaps between the layers of the coil excellent. In addition, the effect of improving the shape is further added.

In the manufacturing method of the armature laminated core according to claim 5, since the notch includes a 45-degree inclined side or a convex curved side and a concave curved side that engage with each other as a pair, The ends of the flat conductors can be made to coincide with each other and can be connected without causing poor bonding.

In the method for manufacturing an armature laminated core according to claim 6, since the magnetic pole is provided in each divided yoke of the armature laminated core, there is no obstacle when winding the coil around the magnetic pole, and the method of the present invention. The coil can be easily formed by the flat conductor.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIGS. 1A and 1B are explanatory diagrams of a method for manufacturing an armature laminated core according to the first embodiment of the present invention, and FIGS. 2A and 2B are second diagrams of the present invention. Explanatory drawing of the manufacturing method of the armature laminated core which concerns on this embodiment FIG. 3: (A), (B) is explanatory drawing of the manufacturing method of the armature laminated core which concerns on the 3rd Embodiment of this invention, FIG. (A), (B) is a notch situation of a flat conductor end part, and explanatory drawing of a connecting part, and Drawing 5 (A) and (B) are explanatory views showing the welding situation of each flat conductor.

First, a method for manufacturing an armature laminated core according to the first embodiment of the present invention will be described with reference to FIG.
As shown in FIG. 1 (A), a part of a strip-shaped flat strip having a thickness in the range of 0.5 to 3 mm, for example, is pressed to the ends of one side (lower bottom) 14 and 15 in the width direction. The first and second flat conductors 10 and 11 connected by the connecting portions 16 and 17 with a desired length are manufactured. The first and second flat plate conductors 10 and 11 are substantially isosceles trapezoidal shapes in which the oblique sides 12 and 13 are 45 degrees with respect to the one side 14 and 15 respectively. The first and second flat conductors 10 and 11 are alternately and continuously formed, and the end portions of the respective one side 14 and 15 are connected by bendable connecting portions 16 and 17 so as to be connected as a whole. A conductor group 18 is formed. As a result, the connecting flat plate conductor group 18 is formed by forming a substantially right isosceles triangular notch 12a leaving the connecting portions 16 and 17 at a predetermined position.

The lengths of the other side (upper bottoms) 19 and 20 in the width direction of the first and second flat conductors 10 and 11 are attached to the magnetic pole 21 of the armature laminated core formed by caulking and integrating the core pieces. The inner die 22 (for example, bobbin made of an insulating material) 22 substantially matches the length and width of the inner die 22 (for example, a range within 2 mm). The widths of the first and second flat conductors 10 and 11 are the same.
The widths of the connecting portions 16 and 17 are, for example, about 0.2 to 2 mm.

The manufacturing method of the armature laminated iron core using the connected flat conductor group 18 will be described. As shown in FIG. 1B, the first flat conductor is formed on one surface of the inner die 22 mounted on the outer side of the magnetic pole 21. 10, and then the connecting portion 16 is bent to bend the second flat plate conductor 11 at a right angle, and the hypotenuses 12 and 13 that are in contact with each other are subjected to electron beam welding or laser welding (in some cases TIG welding or brazing) Then, the flat conductors 10 and 11 are connected to each other.
In this case, the magnetic pole 21 is preferably a magnetic pole of a divided laminated core obtained by dividing the ring-shaped yoke of the laminated iron core for each magnetic pole so that the flat conductors 10 and 11 are wound to form a coil.

Next, the flat conductor 10 connected to the flat conductor 11 is bent at a right angle along the inner die 22 and the hypotenuses 12 and 13 are welded. Then, the flat plate conductors 11 connected to each other are bent at a right angle in the same procedure, and the contact portions are welded. This completes a one-turn winding. The winding of the next turn is performed in the same procedure, but the winding of each turn is formed in a spiral shape and an insulating sheet (not shown) is arranged between the windings. The insulating sheet is preferably formed in a spiral shape in accordance with the winding, but may be a rectangular sheet that is partially separated as long as the insulating distance between the coils is increased.

A coil having a predetermined number of turns is completed by continuing the above operations. In addition, it is preferable to weld the lead | read | reed flat conductor to the starting end part and terminal part of a coil, and this part can be used as a conductor terminal. A copper material is preferable as the first and second flat conductors, but any material can be used.
The technique described in the first embodiment is also applied to the following second and third embodiments.

Next, a method for manufacturing an armature laminated core according to the second embodiment of the present invention will be described. Basically, in the method for manufacturing an armature laminated core according to the first embodiment, An L-shaped flat conductor 30 in which the second flat conductors 10 and 11 are integrated is used.

That is, as shown in FIG. 2 (A), the first piece 26 and the second piece 27 having the same width intersecting at a right angle are provided, and the open side end portions of the first piece 26 and the second piece 27 are inclined by 45 degrees. Thus, the L-shaped flat plate in which the inner sides 28 and 29 of the first piece 26 and the second piece 27 have dimensions corresponding to the length and width of the inner die 22 determined based on the lamination thickness and width of the magnetic pole 21. A connected flat conductor group 32 having a plurality of conductors 30 and connected by a connecting portion 31 that can bend one side (outside side) in the width direction of the open ends of the first piece 26 and the second piece 27 of each flat conductor 30. Is formed from a flat strip material (not shown) by pressing.

In the winding to the magnetic pole 21 of the connection flat conductor group 32, as shown in FIG. 2 (B), the flat conductor 30 at one end of the connection flat conductor group 32 is replaced with the magnetic pole 21 of the armature laminated core. The connecting portion 31 is sequentially bent along the inner mold 22 to be wrapped, and the connecting plate conductor group 32 is wound around the magnetic pole 21 in a spiral manner (that is, adjacent coils are continuous). In this case, a portion where the first piece 26 and the second piece 27 of the adjacent flat conductors 30 abut each other (a 45-degree inclined side 33 which forms a notch) is welded, and further, between adjacent windings. An insulating sheet is inserted to form a coil.

Then, the manufacturing method of the armature laminated core which concerns on the 3rd Embodiment of this invention is demonstrated, referring FIG. 3 (A), (B).
An L-shaped first flat plate conductor 51, a trapezoidal first flat plate conductor 52, an L-shaped second flat plate conductor 53, and a base, each composed of a flat conductor of the same width and connected by a connecting portion 50. The second plate conductors 54 having a shape are repeatedly formed, and the inner sides 55 to 60 of each of the plate conductors 51 to 54 sequentially have the horizontal and vertical dimensions of the inner die 22 of the magnetic pole 21, and these A connecting flat conductor group 63 having a notch 61 in which the adjacent flat conductors 51 to 54 are connected to each other at right angles when the connecting portion 50 that connects both side ends on the outer side of the flat conductors 51 to 54 is bent. Is formed from a flat strip material (not shown).

A connecting portion that connects the L-shaped first flat conductor 51, the trapezoidal first flat conductor 52, the L-shaped second flat conductor 53, and the trapezoidal second flat conductor 54 of the connected flat conductor group 63. The coil 50 is formed by winding spirally around the magnetic pole 21 via the inner die 22 while bending 50, and welding or brazing the locations where the adjacent flat plate conductors 51 to 54 abut each other.
The notch 61 that forms the connecting portion 50 is formed by 45-degree inclined sides 64 and 65 that engage in a pair, but instead of these, a convex curved side and a concave curved side may be used. (See FIG. 4).

According to the third embodiment, the connected flat conductor group 63 includes an L-shaped first flat conductor 51, a second flat conductor 53, a trapezoidal first flat conductor 52, and a second flat conductor. 54 are connected alternately or in a desired order, the coil formed by winding the connected flat conductor group 63 around the magnetic pole 21 includes the first flat conductors 51, 52 and the second flat conductor 53, The locations where the 54 are abutted do not continuously exist on the same line in the coil forming direction. Accordingly, the influence of thickness variation due to the butt is reduced. As a result, non-uniform gaps do not occur between the coil layers, and the electromagnetic characteristics are excellent. The shape is also excellent.

In the above-described embodiment, the butt portions of the respective flat conductors are connected by welding or, in some cases, brazing, but this connection includes metal paste or soldering that melts the connection medium.
Moreover, in the said embodiment, although the side edge part of the location which each flat conductor connects is made into a 45-degree inclination side, as shown to FIG. 4 (A) and (B), it is partial circle shape ( Cutouts 17c composed of a concave curved side 17a and a convex curved side 17b (precisely 45 degrees circle) may be formed at predetermined intervals.

Furthermore, a small triangular notch 16a as shown in FIG. 4 (A) or a semicircular notch 16b as shown in FIG. 4 (B) may be formed on the back side of the connecting portions 16 and 17. . In any of the above cases, adjacent flat conductors are connected in a right angle state when bent at the connecting portion.

Further, as shown in FIGS. 5 (A) and 5 (B), a recess 22a may be provided around the abutting portion 66 of each flat conductor to reduce the thickness to suppress a thickness change due to welding or brazing connection. As a result, it is possible to prevent the surplus 22b generated during welding from protruding in the coil stacking direction.
In the above-described embodiments, specific dimensions and shapes have been specified and described, but the present invention is also applied to modifications and improvements that do not change the gist of the present invention.

(A), (B) is explanatory drawing of the manufacturing method of the armature laminated core which concerns on the 1st Embodiment of this invention. (A), (B) is explanatory drawing of the manufacturing method of the armature laminated core which concerns on the 2nd Embodiment of this invention. (A), (B) is explanatory drawing of the manufacturing method of the armature laminated core which concerns on the 3rd Embodiment of this invention. (A), (B) is an explanatory view of a notch situation of a flat conductor end part and a connection part. (A), (B) is explanatory drawing which shows the welding condition of each flat conductor. (A)-(C) are explanatory drawings of the manufacturing method of the armature laminated core which concerns on a prior art example.

Explanation of symbols

10: first flat conductor, 11: second flat conductor, 12, 13: hypotenuse, 12a: notch, 14, 15: one side, 16, 17: connecting portion, 16a: triangular notch, 16b: Semicircular cutout, 17a: concave curved side, 17b: convex curved side, 17c: cutout, 18: articulated plate conductor group, 19, 20: other side, 21: magnetic pole, 22: inner mold, 22a: Depression, 22b: extra-strip, 26: first piece, 27: second piece, 28, 29: inner side, 30: flat conductor, 31: connecting portion, 32: connected flat conductor group, 33: 45 ° inclined side, 50: connecting portion, 51, 52: first flat conductor, 53, 54: second flat conductor, 55-60: inner side, 61: notch, 63: articulated flat conductor group, 64, 65: 45 degrees Inclined side, 66: Matching point

Claims (6)

In the manufacturing method of the armature laminated core, in which the coil is formed by connecting and winding the flat conductors to the magnetic pole of the armature laminated core formed by laminating and integrating the core pieces,
Each of the first and second flat plate conductors having the same width, which are alternately and continuously arranged in a trapezoidal shape, has one end in the width direction of the adjacent first and second flat plate conductors. An articulated flat plate connected by a foldable connecting portion, and the other side of the first and second flat plate conductors has dimensions corresponding to the vertical and horizontal dimensions of the inner mold determined based on the laminated thickness and width of the magnetic poles. A conductor group is formed from a flat strip material,
The other side of the connecting plate conductor group is aligned with the magnetic pole of the armature laminated core, the connecting portion is bent sequentially, and the connecting plate conductor group is spirally wound around the magnetic pole via the inner mold, A method of manufacturing an armature laminated core, wherein the coil is formed by welding or brazing a portion where the adjacent first and second flat plate conductors abut each other. 2. The method of manufacturing an armature laminated core according to claim 1, wherein the first and second flat plate conductors having a trapezoidal shape can be joined at right angles to each other in the longitudinal direction when bent at the connecting portion. A method for manufacturing an armature laminated iron core, comprising a notch. In the manufacturing method of the armature laminated core, in which the coil is formed by connecting and winding the flat conductors to the magnetic pole of the armature laminated core formed by laminating and integrating the core pieces,
The first piece and the second piece have the same width, and the inner sides of the first piece and the second piece have dimensions corresponding to the length and breadth of the inner mold determined based on the lamination thickness and width of the magnetic poles. A plurality of the L-shaped flat conductors, and one end in the width direction of the flat conductors is connected by a bendable connecting portion, and the open ends of the first piece and the second piece In the part, when bent at the connecting portion, a connected flat conductor group formed with a notch that can be joined at a right angle is formed from a flat strip member,
The inner side of each flat conductor of the connected flat conductor group is aligned with the magnetic pole of the armature laminated core, the connecting portion is bent sequentially, and the connected flat conductor group is spiraled to the magnetic pole via the inner die. A method for manufacturing an armature laminated core, wherein the coil is formed by winding and welding or brazing a location where the adjacent flat conductors meet. In the manufacturing method of the armature laminated core, in which the coil is formed by connecting and winding the flat conductors to the magnetic pole of the armature laminated core formed by laminating and integrating the core pieces,
From the L-shaped first flat plate conductor, the trapezoidal first flat plate conductor, the L-shaped second flat plate conductor, and the trapezoidal second flat plate conductor, which are sequentially connected at the connecting portion with the same width. The inner sides of the respective flat conductors have the vertical and horizontal dimensions of the inner mold of the magnetic poles sequentially, and when the flat conductors are bent at the connecting portion, the adjacent flat conductors are perpendicular to each other. Forming a connecting flat conductor group having a notch connected to the flat strip material;
The L-shaped first flat conductor, the trapezoidal first flat conductor, the L-shaped second flat conductor, and the trapezoidal second flat conductor of the connected flat conductor group are bent at the connecting portion. However, the coil is formed by winding the magnetic pole spirally through the inner mold and welding or brazing the locations where the adjacent flat plate conductors abut each other. Method. The method of manufacturing an armature laminated core according to any one of claims 2 to 4, wherein the notches engage with each other in pairs, a 45-degree inclined side, or a convex curved side and a concave curved side. The manufacturing method of the armature laminated iron core characterized by having provided. The method for manufacturing an armature laminated core according to any one of claims 1 to 5, wherein the magnetic pole is provided in each divided yoke of the armature laminated core. Method.

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