JP2008312352A - Method for forming meandering annular coil and meandering annular coil - Google Patents
Method for forming meandering annular coil and meandering annular coil Download PDFInfo
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- JP2008312352A JP2008312352A JP2007157720A JP2007157720A JP2008312352A JP 2008312352 A JP2008312352 A JP 2008312352A JP 2007157720 A JP2007157720 A JP 2007157720A JP 2007157720 A JP2007157720 A JP 2007157720A JP 2008312352 A JP2008312352 A JP 2008312352A
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- 238000000034 method Methods 0.000 title claims description 22
- 238000010438 heat treatment Methods 0.000 claims abstract description 62
- 238000004804 winding Methods 0.000 claims abstract description 19
- 239000000853 adhesive Substances 0.000 claims abstract description 13
- 230000001070 adhesive effect Effects 0.000 claims abstract description 13
- 239000012790 adhesive layer Substances 0.000 claims description 26
- 238000005452 bending Methods 0.000 claims description 22
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 claims description 14
- 239000011247 coating layer Substances 0.000 claims description 12
- 230000002093 peripheral effect Effects 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 9
- 239000011347 resin Substances 0.000 claims description 9
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 239000003822 epoxy resin Substances 0.000 claims description 5
- 229920000647 polyepoxide Polymers 0.000 claims description 5
- 239000004962 Polyamide-imide Substances 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 229920002312 polyamide-imide Polymers 0.000 claims description 4
- 238000000465 moulding Methods 0.000 abstract description 42
- 238000009413 insulation Methods 0.000 abstract description 9
- 230000001747 exhibiting effect Effects 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 10
- 238000000576 coating method Methods 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 238000007493 shaping process Methods 0.000 description 5
- 238000006073 displacement reaction Methods 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004840 adhesive resin Substances 0.000 description 2
- 229920006223 adhesive resin Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
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- Windings For Motors And Generators (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
本発明は、電動モータのステータに使用する蛇行環状コイルの成形方法及び蛇行環状コイルに関する。 The present invention relates to a method for forming a meandering annular coil used for a stator of an electric motor and a meandering annular coil.
従来、例えば内燃機関と共に車両の駆動源としてハイブリッド車両に搭載される永久磁石式交流モータ等の小型化と部品点数削減を目的として、モータのステータを構成するコイルを蛇行環状コイルにしたものが提案されている（特許文献１、２参照）。該蛇行環状コイルは、周方向に所定のピッチで且つ軸線方向に所定の深さ（高さ）で突出するように複数の蛇行部を備えることによって、ステータの部品点数を削減し、且つステータでの巻線占積率を向上させつつ、コイルエンド高さを低減してモータの軸線方向の寸法を低減して、車両等への積載性を向上させることが可能となるモータを得ることができたものである。
本出願人らは、コイル皮膜にダメージを与えずに量産できる手段として環状コイルを複数回軸方向に蛇行曲げ成形する蛇行環状コイル成形方法を開発し、先に特許出願をした（特願２００７−１１９３７６号）。該蛇行環状コイル成形方法は、コイル始端と終端を外方に突出させてその中間部を複数回旋回して環状巻線した環状コイルを束ねた状態で、軸方向に蛇行曲げ成形するものであった。複雑な環状に蛇行曲げを行う為、各線材の残留応力がそれぞれで異なり、束ねた場合の拘束力が弱いと残留応力に負けて巻線がばらけてしまう。その場合、各線の整列性が悪くなり、次工程の鉄芯組み込み時に疵が付き易くなり、絶縁性にダメージを与える場合が生じることがあった。 The present applicants developed a meandering annular coil forming method in which an annular coil is meandered and bent in the axial direction a plurality of times as means for mass production without damaging the coil coating, and previously filed a patent application (Japanese Patent Application No. 2007- 119376). The meandering annular coil forming method is to meander and bend in the axial direction in a state in which a coil starting end and a terminal end are protruded outward and the intermediate portion is turned a plurality of times and an annular coil wound annularly is bundled. . In order to perform meandering bending in a complicated ring shape, the residual stresses of the respective wires are different from each other, and if the binding force when bundled is weak, the windings are scattered due to the residual stress. In that case, the alignment of each wire is deteriorated, and it becomes easy to be wrinkled when the iron core is assembled in the next process, which may cause damage to the insulation.
そこで、本発明は、蛇行環状コイルの蛇行曲げ成形時に巻線がばらけることを防止し、コンパクトな形状で寸法精度がよく絶縁性に優れた蛇行環状コイルを得ることができる蛇行環状コイルの成形方法及びそれに得られた蛇行環状コイルを提供することを目的とする。 Therefore, the present invention prevents the windings from being scattered during the meandering bending of the meandering annular coil, and it is possible to obtain a meandering annular coil that has a compact shape, has good dimensional accuracy, and is excellent in insulation. It is an object to provide a method and a meandering annular coil obtained therefrom.
上記課題を解決する本発明の蛇行環状コイルの成形方法は、巻線となる線材の外周に接着剤を塗布して接着層（融着層）を形成する工程、該線材を環状コイルに成形する工程、該環状コイルを蛇行曲げ成形をして蛇行環状コイル成形体を得る工程、該蛇行環状コイル成形体を加熱・熱処理用金型に入れ、該加熱・熱処理用金型に固定した状態で加温・熱処理して、前記接着剤を焼付け固化させる工程からなることを特徴とするものである。 The method for forming a meandering annular coil of the present invention that solves the above-mentioned problems is a step of forming an adhesive layer (fused layer) by applying an adhesive to the outer periphery of a wire used as a winding, and forming the wire into an annular coil. A step of bending the annular coil in a meandering manner to obtain a meandering annular coil molded body, and inserting the serpentine annular coil molded body in a heating / heat treatment mold and fixing it to the heating / heat treatment mold. It is characterized by comprising a step of baking and solidifying the adhesive by heating and heat treatment.
また、本発明の蛇行環状コイルの成形方法の他の方法として、巻線となる線材の外周に接着剤を塗布して接着層（融着層）を形成する工程、該線材を環状コイルに成形する工程、該環状コイルを蛇行曲げ成形をして蛇行環状コイル成形体を得る工程、該蛇行環状コイル成形体を最終形状に成形する二次プレス工程、該二次プレスの金型で蛇行環状コイル成形体を挟んで固定した状態で前記二次プレスから金型ユニットを取り外し、金型に固定した状態で加温・熱処理して、前記接着剤を焼付け重合固化させる工程からなることを特徴とする蛇行環状コイルの成形方法も採用することができる。 Further, as another method of forming the meandering annular coil of the present invention, a step of forming an adhesive layer (fusion layer) by applying an adhesive to the outer periphery of the wire used as a winding, and forming the wire into an annular coil A step of bending the annular coil in a meandering manner to obtain a meandering annular coil molded body, a secondary pressing step of forming the meandering annular coil molded body into a final shape, and a meandering annular coil in the mold of the secondary press The mold unit is removed from the secondary press while being fixed with the molded body sandwiched therebetween, and heated and heat-treated while being fixed to the mold, and the adhesive is baked and polymerized and solidified. A method for forming a meandering annular coil can also be employed.
前記蛇行環状コイルの成形方法において、前記線材は銅系の平角線からなる素線の外周部に絶縁被覆層を有するものであり、該絶縁被覆層がポリアミドイミド系樹脂で形成されているのが望ましい。さらに、前記接着層はエポキシ系樹脂で形成されているのが望ましい。 In the method of forming the meandering annular coil, the wire has an insulating coating layer on the outer peripheral portion of a strand made of a copper-based rectangular wire, and the insulating coating layer is formed of a polyamideimide resin. desirable. Further, the adhesive layer is preferably formed of an epoxy resin.
また、上記課題を解決する本発明の蛇行環状コイルは、軸方向に蛇行部を有する蛇行環状コイルであって、素線の外周部に絶縁被覆層を有し、かつ該絶縁被覆層の外周部に接着層を有してなる被覆線材で巻線コイルが形成され、該巻線コイル外周面に位置する被覆線材同士の接着層が互いに重合固化して一体となっていることを特徴とするものである。 The meandering annular coil of the present invention that solves the above-mentioned problem is a meandering annular coil having a meandering portion in the axial direction, and has an insulating coating layer on the outer peripheral portion of the strand, and the outer peripheral portion of the insulating coating layer A wound coil is formed of a covered wire material having an adhesive layer on the wire, and the adhesive layers of the covered wire materials positioned on the outer peripheral surface of the wound coil are polymerized and solidified to be integrated. It is.
請求項１〜５に記載の発明によれば、巻線の各線がきちんと整列して、絶縁性が高く、コンパクトな形状で次工程での鉄芯組み込み時に疵が付きにくく、寸法精度の高い蛇行環状コイルを得ることができる。従って、車両等への積載性を向上させることが可能となるモータを得ることができる。その上、環状コイル成形体の熱処理は、蛇行成形プレスの金型から一旦取外して、他の熱処理金型で行う（請求項１）か、あるいは二次成形プレスの金型ごと取外してプレス本体とは別に行う（請求項２）ので、接着剤を焼き付け固化させるのに時間を要しても、その間プレス成形作業を続けることができ、装置の稼動率を高めることができる。 According to the first to fifth aspects of the present invention, the winding wires are neatly aligned, have high insulation, have a compact shape, and are difficult to be wrinkled when the iron core is assembled in the next process, and have high dimensional accuracy. An annular coil can be obtained. Accordingly, it is possible to obtain a motor that can improve the loadability on a vehicle or the like. In addition, the heat treatment of the annular coil molded body is once performed by removing it from the die of the meandering press and using another heat treatment die (Claim 1), or by removing the die of the secondary forming press together with the press main body. Since it is performed separately (claim 2), even if it takes time to bake and solidify the adhesive, the press molding operation can be continued during that time, and the operating rate of the apparatus can be increased.
請求項３の記載の発明によれば、絶縁被覆層は耐熱性、耐久性、耐摩耗性に優れ、且つ層厚が厚いのでピンホールの発生や組み込み時の疵に対しても絶縁性を破壊することがなく、絶縁性に優れた蛇行環状コイルを得ることができる。また、請求項４の発明によれば、接着剤を巻線形成前の線材に直接塗布することができ、乾燥させた状態で成形することによって金型へ付着することなく蛇行環状コイルを成形することができる。且つ成形後熱処理することによって、容易に重合固化させることができ、蛇行環状コイルがばらけることを確実に防止することができる。 According to the invention described in claim 3, the insulating coating layer is excellent in heat resistance, durability, and wear resistance, and has a large layer thickness, so that the insulation is destroyed against occurrence of pinholes and wrinkles during installation. Thus, a meandering annular coil excellent in insulation can be obtained. According to the invention of claim 4, the adhesive can be directly applied to the wire before forming the winding, and the meandering annular coil is formed without being attached to the mold by forming in a dried state. be able to. Further, by heat treatment after molding, it can be easily polymerized and solidified, and it is possible to reliably prevent the meandering annular coil from being scattered.
以下、本発明の望ましい実施形態を図面に基づき詳細に説明する。
本実施形態の蛇行環状コイル１０は、図３に示すように素線２として純銅系の平角線、あるいはその表面にニッケルめっき等の表面処理を施したものを採用し、その外周部に絶縁皮膜層３を形成し、さらにその外周部に接着層４を形成している。絶縁皮膜層３として、ポリアミドイミド系樹脂その他の耐熱性、耐摩耗性、耐久性がある樹脂であれば特に限定されない。絶縁被覆層の形成は、複数回の溶融樹脂の重ね塗りによって形成できるが、均一性を確保する皮膜形成法として素線２に対して絶縁樹脂を押出成形により外周部を被覆するように連続成形する方法が好ましい。
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
As shown in FIG. 3, the meandering annular coil 10 of the present embodiment employs a pure copper-based rectangular wire as the element wire 2 or a surface treated with nickel plating or the like on its surface, and an insulating film on its outer peripheral portion. The layer 3 is formed, and the adhesive layer 4 is further formed on the outer periphery thereof. The insulating film layer 3 is not particularly limited as long as it is a polyamide-imide resin or other resin having heat resistance, wear resistance, and durability. The insulation coating layer can be formed by multiple coatings of molten resin, but as a film formation method to ensure uniformity, the insulation resin is extruded on the strand 2 so that the outer periphery is covered by extrusion molding. Is preferred.
接着層としては、一般的な接着樹脂が採用でき、例えばエポキシ系樹脂、フェノール系樹脂、ウレタン系樹脂、メラミン系樹脂、ユリア系樹脂、不飽和ポリエステル系樹脂等が採用できる。接着層は、成形の際金型への付着を防止するために、素線に塗布後乾燥させておき、成形後に加温・熱処理により、固化して隣接する線材の接着層同士が溶融接着して一体になるものが好ましい。接着層の厚さは、コイル成形後に絶縁被覆された素線がばらけない程度に相互に接着可能であればよい。 As the adhesive layer, a general adhesive resin can be employed. For example, an epoxy resin, a phenol resin, a urethane resin, a melamine resin, a urea resin, an unsaturated polyester resin, or the like can be employed. In order to prevent the adhesion layer from adhering to the mold during molding, it is dried after being applied to the strands, solidified by heating and heat treatment after molding, and the adhesion layers of adjacent wires melt and bond together. Are preferably integrated. The thickness of the adhesive layer only needs to be able to adhere to each other to such an extent that the insulated wires after the coil molding are not scattered.
以上のようにして断面構造が中心部より銅／絶縁被覆／接着層からなる被覆線５を得、該被覆線により図１に示すような、環状コイル６を成形する。本実施形態の環状コイル６は、両端部が外方に突出して端子７、８を形成し、断面が図３（Ｂ）に示すように、５巻２段に形成されているが、必ずしもそれに限るものでなく、モータの定格に応じて適宜選定される。該環状コイル６を前記、例えば前記特願２００７−１１９３７６号に示すような蛇行環状コイル成形機を用いて、その上金型ユニット及び下金型ユニットにより、蛇行曲げ成形により直径方向に縮径しながら軸方向に突出して蛇行する蛇行部を成形して蛇行環状コイル１を得る。蛇行環状コイル１は、図２に示すように、ステータの軸方向にクランク状に蛇行する複数(本実施形態では１０個)の蛇行部１１を有している。得られた蛇行環状コイル１は蛇行曲げ成形による各被覆線５の残留応力により巻線がある程度ばらけた状態になっている。 As described above, a coated wire 5 having a cross-sectional structure of copper / insulating coating / adhesive layer is obtained from the center, and an annular coil 6 as shown in FIG. 1 is formed from the coated wire. The annular coil 6 of the present embodiment has both ends protruding outward to form terminals 7 and 8, and the cross section is formed in five stages and two stages as shown in FIG. It is not limited and is appropriately selected according to the rating of the motor. The annular coil 6 is reduced in diameter in the diametrical direction by meandering bending with the upper die unit and the lower die unit using the meandering annular coil forming machine as shown in, for example, Japanese Patent Application No. 2007-119376. The meandering annular coil 1 is obtained by forming a meandering portion that projects in the axial direction while meandering. As shown in FIG. 2, the meandering annular coil 1 has a plurality (ten in this embodiment) meandering portions 11 meandering in a crank shape in the axial direction of the stator. The obtained meandering annular coil 1 is in a state where the windings are scattered to some extent by the residual stress of each covered wire 5 by meandering bending.
図５及び図６は、特願２００７−１１９３７６号に示す蛇行環状コイル成形機による蛇行環状コイル１の成形方法を示している。この環状巻線コイル成形機は、円周方向に等間隔で離間された複数の蛇行曲げ成形上金型５４を有する上金型ユニット５０と、円周方向に前記等間隔と同一間隔で離間され各々が隣接する前記上金型５４の間に配置される複数の下金型６４を有する下金型ユニット６０とを備え、前記下金型６４の各々は環状コイル６を保持するコイル保持部６７を有しており、該コイル保持部６７で保持された環状コイル６に対して前記上金型ユニット５０の軸方向の変位に応じて前記環状コイル６を径方向に縮小させるコイル径縮小手段(カム面５６，６６)を前記上金型ユニット５０及び前記下金型ユニット６０にそれぞれ設けてある。 5 and 6 show a method of forming the meandering annular coil 1 by the meandering annular coil forming machine shown in Japanese Patent Application No. 2007-119376. This annular winding coil forming machine includes an upper mold unit 50 having a plurality of meandering bending upper molds 54 spaced apart at equal intervals in the circumferential direction, and spaced apart at equal intervals in the circumferential direction. A lower die unit 60 having a plurality of lower dies 64 disposed between the upper dies 54 adjacent to each other, and each of the lower dies 64 holds a coil holding portion 67 for holding the annular coil 6. Coil diameter reducing means for reducing the annular coil 6 in the radial direction in accordance with the axial displacement of the upper mold unit 50 with respect to the annular coil 6 held by the coil holding portion 67. Cam surfaces 56 and 66) are provided on the upper mold unit 50 and the lower mold unit 60, respectively.
この装置による蛇行環状コイルの成形は、環状コイル６を下金型ユニット６０の各下金型６４の金型ベース６２で保持し、コイル保持部６７を金型ベース６２に固定して行う。この状態から、上金型ユニット５０を下降させることにより、上金型ユニット５０のローラ５２が下金型ユニット６０のローラガイド６５のカム面６６に当接するため、上金型ユニット５０の軸方向変位量に対して環状コイル６が半径方向へ縮小変化すると共に軸線方向へ変位する。同様に下金型ユニット６０のローラ６３が上金型ユニット５０のローラガイドのカム面５６に当接するため、金型ベース６２がカム面の形状に応じてガイドレール６８に沿って半径方向に変位する。このように、特殊形状の曲面状カムを採用することにより、環状コイル６の軸方向変位量に対して径方向変位量の比率を連続的に変化させることができるため、環状コイル６に無理なストレスを与えることなく、複数の蛇行部１１を有する蛇行環状コイル１を自動的に形成することができる。 The meandering annular coil is formed by this apparatus by holding the annular coil 6 by the mold base 62 of each lower mold 64 of the lower mold unit 60 and fixing the coil holding portion 67 to the mold base 62. When the upper mold unit 50 is lowered from this state, the roller 52 of the upper mold unit 50 comes into contact with the cam surface 66 of the roller guide 65 of the lower mold unit 60. The annular coil 6 is reduced in the radial direction and displaced in the axial direction with respect to the displacement. Similarly, since the roller 63 of the lower mold unit 60 contacts the cam surface 56 of the roller guide of the upper mold unit 50, the mold base 62 is displaced in the radial direction along the guide rail 68 according to the shape of the cam surface. To do. As described above, by adopting the specially-shaped curved cam, the ratio of the radial displacement amount to the axial displacement amount of the annular coil 6 can be continuously changed. The meandering annular coil 1 having a plurality of meandering portions 11 can be automatically formed without applying stress.
このようにして得られた蛇行環状コイル１を、成形機から取り出して予め用意してある蛇行環状コイルの所望の最終寸法に形成された例えば図４に示すような加熱・熱処理用金型１５に入れて固定し、固定した状態で加温・熱処理して、接着層を焼き付け重合固化させる。接着層の熱処理は、蛇行環状コイル成形機で成形終了後、その上金型ユニット５０及び下金型ユニット６０に固定保持された状態で該金型ユニット自体を内部より加熱して熱処理してもよいが、接着剤を焼き付け重合固化するのにかなりの時間を要するので、その間成形機の稼動を停止しなければならず、稼動率が低下するため、本実施形態では、成形機の金型ユニットとは別に蛇行環状コイルの最終形状をした専用の加熱・熱処理用金型１５を用意し、成形機の稼動率を向上させるようにした。 The meandering annular coil 1 obtained in this way is taken out from the molding machine and formed into a desired final dimension of a meandering annular coil prepared in advance, for example, in a heating / heat treatment mold 15 as shown in FIG. Then, the adhesive layer is baked and solidified by heating and heat treatment in the fixed state. The heat treatment of the adhesive layer may be performed by heating the die unit itself from the inside in a state of being fixedly held by the upper die unit 50 and the lower die unit 60 after completion of molding by the meandering annular coil molding machine. However, since it takes a considerable time to bake and solidify the adhesive, the operation of the molding machine must be stopped during that time, and the operation rate is lowered. Therefore, in this embodiment, the mold unit of the molding machine is used. Apart from that, a dedicated heating / heat treatment mold 15 having the final shape of the meandering annular coil was prepared to improve the operating rate of the molding machine.
加熱・熱処理用金型１５は、蛇行部の形状に対応する凹部１６が所定ピッチで形成された加熱・熱処理用下金型１７と、凹部１６に嵌合して凹部との間で蛇行環状コイルの蛇行部１１を挟んで押圧加熱する凸部１９を有する加熱・熱処理用上金型１８から構成され、内部に加熱用ヒータを有し、蛇行環状コイルを挟んで固定した状態で加温して、蛇行環状コイルを熱処理する。該加熱・熱処理用金型１５は、焼き付け時の熱で変形が少ない耐熱合金で形成され、且つ熱処理後の蛇行環状コイルの離型性に優れているものが望ましく、例えば型面をフッ素系樹脂をコーティングするのが望ましい。
焼き付け固化の熱処理温度は、接着層４を構成する樹脂によって相違するが、接着性樹脂を重合固化させかつ内層の絶縁皮膜層に影響を与えない程度でなければならない。また、金型固定の際に、圧力をかけ接着面積を大きくするのが望ましい。しかしながら、その場合の圧力も内層の絶縁皮膜層に影響与えない程度でなければならない。
The heating / heat treatment mold 15 includes a heating / heat treatment lower mold 17 in which concave portions 16 corresponding to the shape of the meandering portion are formed at a predetermined pitch, and a serpentine annular coil between the concave portion 16 and the concave portion 16. The heating and heat treatment upper mold 18 having a convex portion 19 that is pressed and heated across the meandering portion 11 of the above, has a heating heater inside, and is heated in a state of being fixed with the meandering annular coil sandwiched between them. The serpentine annular coil is heat treated. The heating / heat treatment mold 15 is preferably formed of a heat-resistant alloy that is less deformed by heat during baking, and is excellent in releasability of the meandering annular coil after the heat treatment. It is desirable to coat.
The heat treatment temperature for baking and solidification varies depending on the resin constituting the adhesive layer 4, but must be such that the adhesive resin is polymerized and solidified and does not affect the inner insulating film layer. In addition, it is desirable to increase the bonding area by applying pressure when fixing the mold. However, the pressure in that case must be such that it does not affect the inner insulating film layer.
以上のように、蛇行曲げ成形後の蛇行環状コイルを最終形状に形成されている加熱・熱処理用金型１５に保持して熱処理することによって、接着層４が図３（Ｃ）に示すように、接触している被覆線５の接着層４同士が接着して一体となって、蛇行環状コイルの外周部全体が均一に接着層で一体に被覆された状態になり、ばらけた状態が補正され、最終形状に修正された蛇行環状コイル１０を得ることができ、次工程の鉄芯組み込みがスムーズにでき、組み込み時の疵付きを防止することができる。
また、蛇行曲げ成形後の蛇行環状コイルを最終形状に形成されている加熱・熱処理用金型１５に保持した状態で加熱炉などに入れ、加熱・熱処理を行ってもよい。
As described above, the adhesive layer 4 is formed as shown in FIG. 3C by holding and heating the meandering annular coil after the meandering bending to the heating / heat treatment mold 15 formed in the final shape. The adhesive layers 4 of the covered wire 5 that are in contact with each other are bonded and integrated, and the entire outer peripheral portion of the meandering annular coil is uniformly covered with the adhesive layer, and the scattered state is corrected. The meandering annular coil 10 corrected to the final shape can be obtained, and the iron core can be smoothly assembled in the next process, and wrinkles during the assembly can be prevented.
Alternatively, the meandering annular coil after meandering bending may be placed in a heating furnace or the like while being held in the heating / heat treatment mold 15 formed in the final shape, and the heating / heat treatment may be performed.
次に本発明に係る蛇行環状コイルの成形方法の他の実施形態について説明する。
本実施形態に係る成形方法は、上金型ユニット及び下金型ユニットを用いた蛇行曲げ成形により蛇行環状コイルを成形するまでの工程は前記実施形態と同様であるが、本実施形態では、その後さらに前記金型ユニットから取り出した後、最終形状に二次プレス成形機により成形を行い、該二次プレス成形機の金型で蛇行環状コイルを挟んだ状態で金型ごと取り外し、金型に固定した状態で加温・熱処理し、接着層を焼き付け重合固化させるようにしたことを特徴とするものである。
Next, another embodiment of the method for forming a meandering annular coil according to the present invention will be described.
In the molding method according to the present embodiment, the process until the meandering annular coil is molded by meandering bending using the upper mold unit and the lower mold unit is the same as that of the previous embodiment. Further, after taking out from the mold unit, the final shape is formed by a secondary press molding machine, and the mold is removed with the meandering annular coil sandwiched between the molds of the secondary press molding machine and fixed to the mold. In this state, the adhesive layer is baked and polymerized and solidified by heating and heat treatment.
図７（Ａ）は、環状コイルを前記実施形態と同様に成形機により蛇行曲げ成形により形成された蛇行環状コイルをさらに、プレスして最終形状に成形する二次プレス上金型ユニット２４と二次プレス下金型ユニット３０を備えた二次プレス成形機２０を示している。また、図７（Ｂ）は、二次プレス上金型ユニット２４と二次プレス下金型ユニット３０により蛇行環状コイルを固定保持した状態の要部断面図を示している。
二次プレス成形機２０は、上側治具２２に固定された上金型２３ａ、２３ｂを備えた二次プレス上金型ユニット２４と、下側治具２５に固定された内径枠２６と外径枠２７内に下金型２８ａ、２８ｂを備えた二次プレス下金型ユニット３０を有し、上側治具２２及び下側治具２５は、同図（Ｂ）に示すように蛇行環状コイルを加圧固定した状態で、同図（Ａ）で仮想線３１で示す部分が二次プレス成形機のベース本体３２、３３から容易に脱着できるように構成されている。
FIG. 7 (A) shows a secondary press upper die unit 24 and a second press unit that presses a meandering coil formed by meandering bending with a molding machine in the same manner as in the previous embodiment to form a final shape. The secondary press molding machine 20 provided with the next press lower die unit 30 is shown. FIG. 7B shows a cross-sectional view of the main part in a state in which the meandering annular coil is fixedly held by the secondary press upper die unit 24 and the secondary press lower die unit 30.
The secondary press molding machine 20 includes a secondary press upper mold unit 24 having upper molds 23a and 23b fixed to the upper jig 22, an inner diameter frame 26 fixed to the lower jig 25, and an outer diameter. A secondary press lower die unit 30 having lower dies 28a and 28b in a frame 27 is provided, and the upper jig 22 and the lower jig 25 are provided with meandering annular coils as shown in FIG. In a state where the pressure is fixed, the portion indicated by the imaginary line 31 in FIG. 3A is configured so that it can be easily detached from the base bodies 32 and 33 of the secondary press molding machine.
前記実施形態と同様に蛇行環状コイル成形機により蛇行曲げ成形されて形成された蛇行環状コイルをさらに二次プレス成形機２０にセットして二次プレス上金型ユニット２４と二次プレス下金型ユニット３０で最終形状に成形し、金型で所定圧の加圧状態で挟んだ状態で、必要に応じて二次プレス上金型ユニット２４と二次プレス下金型ユニット３０を冶具などの使用により固定し、その状態で二次プレス上金型ユニット２４及び二次プレス下金型ユニット３０をベース本体３２・３３から取り外し、金型で固定した状態で加熱炉に入れて加温・熱処理を行い、接着層を焼き付け重合固化させる。その場合、接着層の材質、焼付け固化の熱処理温度条件等は前記実施形態と同様な条件が採用できる。本実施形態の場合は、蛇行環状コイル成形機で成形後さらに、二次プレス成形機で成形する成形工程を含んでいる場合であり、二次プレス成形機の金型ユニットは、蛇行環状コイル成形機の金型ユニットの場合と比べて駆動機構が単純であり、金型ユニット自体を二次プレス成形機の駆動機構と容易に脱着可能に構成できるので、二次プレス成形機の金型を複数個用意しておき、脱着可能にすることによって、熱処理時間に関わらず稼働率を上げるようにした。 In the same manner as in the above embodiment, the meandering annular coil formed by meandering bending by the meandering annular coil molding machine is further set in the secondary press molding machine 20 and the secondary press upper die unit 24 and the secondary press lower die. Using a tool such as a jig for the secondary press upper die unit 24 and the secondary press lower die unit 30 as necessary, with the unit 30 being molded into a final shape and sandwiched by a die with a predetermined pressure. In this state, the secondary press upper die unit 24 and the secondary press lower die unit 30 are detached from the base main bodies 32 and 33, and are fixed in the die and placed in a heating furnace for heating and heat treatment. The adhesive layer is baked and polymerized and solidified. In this case, the same conditions as in the above embodiment can be adopted for the material of the adhesive layer, the heat treatment temperature condition for baking and solidification, and the like. In the case of the present embodiment, it is a case in which a molding step of molding with a secondary press molding machine is included after molding with a serpentine annular coil molding machine, and the mold unit of the secondary press molding machine is a serpentine annular coil molding. Compared to the mold unit of the machine, the drive mechanism is simple, and the mold unit itself can be configured to be easily detachable from the drive mechanism of the secondary press molding machine, so there are multiple molds for the secondary press molding machine. By preparing them individually and making them detachable, the operating rate was increased regardless of the heat treatment time.
素線として純銅系の平角線を採用し、該素線にポリアミドイミド樹脂を数回塗布焼付けで被覆して絶縁皮膜を形成した。その表面に、さらにエポキシ系樹脂を塗布して接着層を形成して、該接着層を乾燥させて被覆線を得た。該被覆線により、５巻２段の環状コイル６を成形し、該環状コイル６を蛇行環状コイル成形機により蛇行曲げ成形して、蛇行環状コイル１を得た。得られた蛇行環状コイルを加熱熱処理用金型に入れて、加圧固定状態で保持して所定の金型内面温度で所定時間保持して、蛇行環状コイル１０を得た。
得られた蛇行環状コイル１０は、ばらけがなく整列状態を維持しており、複数箇所のコイル外径、内径、及びコイル幅（高さ）を測定して最大値、最小値、平均値を求めたが何れも基準内にあり、また、外観、触感上もコイルはばらけてなく、本発明の有効性が確認された。
A pure copper-based rectangular wire was adopted as the element wire, and the polyamideimide resin was applied to the element wire several times by coating and baking to form an insulating film. An epoxy resin was further applied to the surface to form an adhesive layer, and the adhesive layer was dried to obtain a coated wire. An annular coil 6 having five turns and two stages was formed from the covered wire, and the annular coil 6 was meandered and bent by a meandering annular coil forming machine, whereby the meandering annular coil 1 was obtained. The obtained meandering annular coil was put into a heat treatment mold, held in a pressure-fixed state, and kept at a predetermined die inner surface temperature for a predetermined time, whereby a meandering annular coil 10 was obtained.
The obtained meandering annular coil 10 is maintained in an aligned state without variation, and the maximum value, minimum value, and average value are obtained by measuring the coil outer diameter, inner diameter, and coil width (height) at a plurality of locations. However, all were within the standards, and the coil was not scattered in terms of appearance and touch, confirming the effectiveness of the present invention.
素線として純銅系の平角線を採用し、該素線にポリアミドイミド樹脂を数回塗布焼付けで被覆しての絶縁皮膜を形成した。その表面に、さらにエポキシ系樹脂を塗布して接着層を形成して、該接着層を乾燥させて被覆線を得た。該被覆線により、５巻２段の環状コイル６を成形し、該環状コイル６を蛇行環状コイル成形機により蛇行曲げ成形して、蛇行環状コイル１を得た。蛇行環状コイル成形機により蛇行曲げ成形されて形成された蛇行環状コイルを、さらに二次プレス成形機２０にセットして、二次プレス上金型ユニット２４と二次プレス下金型ユニット３０で最終形状に成形し、金型で所定圧の加圧状態で挟んだ状態で、二次プレス上金型ユニット２４と二次プレス下金型ユニット３０とを冶具を使って固定し、ベース本体から取り外し、加熱炉に入れて加温・熱処理を行い、蛇行環状コイルの温度が所定温度で所定時間保持して接着層を焼き付け重合固化させることによって、蛇行環状コイル１０を得た。
得られた蛇行環状コイル１０は、ばらけがなく整列状態を維持しており、複数箇所のコイル外径、内径、及びコイル幅（高さ）を測定して最大値、最小値、平均値を求めたが何れも基準内にあり、また、外観、触感上もコイルはばらけてなく、本発明の有効性が確認された。
A pure copper-based rectangular wire was adopted as the element wire, and an insulating film was formed by coating the element wire with a polyamidoimide resin several times by baking. An epoxy resin was further applied to the surface to form an adhesive layer, and the adhesive layer was dried to obtain a coated wire. An annular coil 6 having five turns and two stages was formed from the covered wire, and the annular coil 6 was meandered and bent by a meandering annular coil forming machine, whereby the meandering annular coil 1 was obtained. The meandering annular coil formed by meandering bending by the meandering annular coil molding machine is further set in the secondary press molding machine 20, and finally the secondary press upper die unit 24 and the secondary press lower die unit 30. The secondary press upper die unit 24 and the secondary press lower die unit 30 are fixed with a jig and removed from the base body while being molded into a shape and sandwiched by a mold with a predetermined pressure. Then, heating and heat treatment were carried out in a heating furnace, and the temperature of the meandering annular coil was maintained at a prescribed temperature for a prescribed time, and the adhesive layer was baked and solidified to obtain a meandering annular coil 10.
The obtained meandering annular coil 10 is maintained in an aligned state without variation, and the maximum value, minimum value, and average value are obtained by measuring the coil outer diameter, inner diameter, and coil width (height) at a plurality of locations. However, all were within the standards, and the coil was not scattered in terms of appearance and touch, confirming the effectiveness of the present invention.
本発明の蛇行環状コイルの成形方法及び蛇行環状コイルは、ハイブリッド車両用モータ、電気自動車用モータのステータ巻線として特に好適に利用できるが、それに限らず、一般的なステータコイルのばらけ防止に利用可能である。 The method for forming a meandering annular coil and the meandering annular coil of the present invention can be particularly suitably used as a stator winding of a motor for a hybrid vehicle and a motor for an electric vehicle. Is available.
１ 蛇行環状コイル（熱処理前） ２ 素線
３ 絶縁被覆層 ４ 接着層
５ 被覆線 ６ 環状コイル
７、８ 端子 １０ 蛇行環状コイル（熱処理後）
１１ 蛇行部 １５ 加熱・熱処理用金型
１６ 凹部 １７ 加熱・熱処理用下金型
１８ 加熱・熱処理用上金型 １９ 凸部
２０ 二次プレス成形機 ２２ 上側冶具
２３ａ、２３ｂ 二次プレス上金型 ２４ 二次プレス上金型ユニット
２５ 下側冶具 ２６ 内径枠
２７ 外径枠 ２８ａ、２８ｂ 二次プレス下金型
３０ 二次プレス下金型ユニット ３１ 仮想線
３２、３３ ベース本体 ５０ 蛇行曲げ成形上金型ユニット
５２、６３ ローラ ５４ 蛇行曲げ成形上金型
５６、６６ カム面 ６０ 蛇行曲げ成形下金型ユニット
６２ 蛇行曲げ成形金型ベース ６４ 蛇行曲げ成形下金型
６５ ローラガイド ６７ コイル保持部
６８ ガイドレール
DESCRIPTION OF SYMBOLS 1 Serpentine ring coil (before heat processing) 2 Wire 3 Insulation coating layer 4 Adhesion layer 5 Covered wire 6 Ring coil 7, 8 Terminal 10 Serpentine ring coil (After heat treatment)
DESCRIPTION OF SYMBOLS 11 Meandering part 15 Heating / heat processing metal mold | die 16 Recessed part 17 Heating / heat processing lower metal mold | die 18 Heating / heat processing upper metal mold | die 19 Convex part 20 Secondary press molding machine 22 Upper jig 23a, 23b Secondary press upper metal mold | die 24 Secondary press upper mold unit 25 Lower jig 26 Inner diameter frame 27 Outer diameter frame 28a, 28b Secondary press lower mold 30 Secondary press lower mold unit 31 Virtual wire 32, 33 Base body 50 Serpentine bending upper mold Unit 52, 63 Roller 54 Serpentine bending upper mold 56, 66 Cam surface 60 Serpentine bending lower mold unit 62 Serpentine bending mold base 64 Serpentine bending lower mold 65 Roller guide 67 Coil holder 68 Guide rail
Claims (5)
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| Application Number | Priority Date | Filing Date | Title |
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| JP2007157720A JP2008312352A (en) | 2007-06-14 | 2007-06-14 | Method for forming meandering annular coil and meandering annular coil |
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| Application Number | Priority Date | Filing Date | Title |
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| JP2007157720A JP2008312352A (en) | 2007-06-14 | 2007-06-14 | Method for forming meandering annular coil and meandering annular coil |
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| JP2008312352A true JP2008312352A (en) | 2008-12-25 |
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| JP2007157720A Withdrawn JP2008312352A (en) | 2007-06-14 | 2007-06-14 | Method for forming meandering annular coil and meandering annular coil |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014090613A (en) * | 2012-10-31 | 2014-05-15 | Toyota Motor Corp | Method of manufacturing segment coil |
| CN110383640A (en) * | 2017-03-01 | 2019-10-25 | 日立汽车系统株式会社 | Coil wire used in stator, rotating electric machine, the manufacturing method of stator, the manufacturing method of rotating electric machine and stator |
| CN114737042A (en) * | 2022-04-18 | 2022-07-12 | 福建龙溪轴承(集团)股份有限公司 | High-frequency induction heat treatment device for spherical outside surface of inner ring of joint bearing |
| WO2023032415A1 (en) * | 2021-08-31 | 2023-03-09 | 株式会社セルコ | Method for manufacturing coil and jig for bending coil |
-
2007
- 2007-06-14 JP JP2007157720A patent/JP2008312352A/en not_active Withdrawn
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014090613A (en) * | 2012-10-31 | 2014-05-15 | Toyota Motor Corp | Method of manufacturing segment coil |
| CN110383640A (en) * | 2017-03-01 | 2019-10-25 | 日立汽车系统株式会社 | Coil wire used in stator, rotating electric machine, the manufacturing method of stator, the manufacturing method of rotating electric machine and stator |
| WO2023032415A1 (en) * | 2021-08-31 | 2023-03-09 | 株式会社セルコ | Method for manufacturing coil and jig for bending coil |
| CN114737042A (en) * | 2022-04-18 | 2022-07-12 | 福建龙溪轴承(集团)股份有限公司 | High-frequency induction heat treatment device for spherical outside surface of inner ring of joint bearing |
| CN114737042B (en) * | 2022-04-18 | 2024-06-11 | 福建龙溪轴承(集团)股份有限公司 | High-frequency induction heat treatment device for outer spherical surface of inner ring of joint bearing |
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