JP2009225513A - Method for forming coil member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To form a coil member which is densely wound while employing a split flat wire structure by gathering a plurality of wires in a flat shape. <P>SOLUTION: As for four coil wires 11 unwound from bobbins 30a-30d, a travelling tendency correcting section 35 uses a straightener to straighten the travelling tendency such as bending in a lateral direction and twisting, and the coil wires are gathered in a curl correcting section 37 to straighten the curl tendency by a curl straightener. Then, in a winding section 40, the split flat wire 10 is wound many turns, thereby forming a coil member 20, which is thereafter resin-molded to obtain the coil member as a cassette coil. Wire tendency such as travelling tendency or curl tendency is straightened, thereby gaps in the split flat wire 10 can be eliminated as much as possible and the highly densely coil member 20 can be obtained. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for forming a coil member having a structure in which a plurality of coil wires are bundled and wound into divided rectangular wires.

  In general, a coil member disposed in a motor, a generator, a reactor, a transformer, or the like is configured by winding a thin copper wire many times. For example, a motor stator generally has a structure in which a coil with a substantially circular cross section is wound around a tooth portion of a core or a split core, but recently, a structure using a flat wire called a flat wire is also used. Has been proposed.

For example, in Patent Document 1, a plurality of copper wires are incorporated into a planar multi-core wire (divided rectangular wire), and the whole is wound in an edgewise shape, thereby reducing eddy loss.
In Patent Document 2, a plurality of coil portions wound by bundling a plurality of coil wires into divided rectangular wires are prepared by gradually increasing their diameters, and the respective coil portions are sequentially fitted concentrically. A method is disclosed.

JP 2005-327834 A JP 2005-209916 A

  With such a structure in which a plurality of coil wires are bundled into divided rectangular wires, a large current can flow, and the torque of the motor can be increased. Moreover, the slot region of the stator can be effectively used by eliminating a gap when the coil wire is wound in multiple layers from the lower layer to the upper layer.

  However, in order to bundle and wind a plurality of coil wires at a high density in a split rectangular wire, it is necessary to take measures against various stresses and deformations acting on each coil wire. In this technique, no specific measures are taken, and it is practically difficult to assemble a coil member having a high-density divided rectangular wire structure.

  An object of the present invention is to provide a method for forming a coil member having a divided rectangular wire structure in which a plurality of coil wires are gathered at high density.

  The method for forming a coil member according to the present invention is a method in which a plurality of coil wires are unwound from a bobbin and the assembled divided rectangular wires are wound around a core while correcting the wrinkles of the coil wires. There are two types of wire rods: winding rods that are generated mainly when the coil wire is wound around the bobbin, and traveling rods that are mainly generated by bending or twisting when the coil wire is traveling. Done with.

When a plurality of coil wires having a rectangular cross section are gathered by this method, they are collected into one flat wire, so-called divided flat wire, with almost no gap. And the coil member wound by high density is obtained by forming this division | segmentation rectangular wire in the shape which winds a core.
Further, when the coil current frequency is f, the coil wire width is d, the magnetic flux density amplitude is Bmax, and the resistivity of the coil material is ρ, the coil vortex loss w is expressed by the following formula (1).
w = π ² f ² d ² Bmax ² / 6ρ (1)
Represented by Since the coil wire width is reduced to (1 / number of coil wires), the coil vortex loss w is reduced.

  In the method for forming a coil member according to the present invention, the traveling wrinkles of a plurality of coil wires are individually corrected, while the plurality of coil wires are assembled into divided rectangular wires, and then the winding wrinkles of the respective coil wires are simultaneously corrected. By reducing the number of straighteners required, the process of correcting curling can be simplified.

  Since the coil member has an edgewise shape, a portion corresponding to the corner portion of the core can be bent with a small curvature radius. Therefore, coupled with the fact that there are almost no gaps in the divided rectangular wires, it is possible to reduce unnecessary gaps between the coil and the core, and downsizing motors, generators, reactors, transformers, etc., to which the coil members are mounted. Can be achieved.

  By using a plurality of bobbins individually traversable as a bobbin wound with a plurality of coil wires, the position where each coil wire is unwound can be held almost constant, so that stable correction is possible. Processing can be performed.

  By bending the divided rectangular wire to an angle exceeding the set bending angle, the deviation from the set bending angle due to the spring back can be suppressed as much as possible.

  The coil member can be used as a cassette coil by molding the wound divided rectangular wire with resin.

  According to the method for forming a coil member of the present invention, it is possible to form a coil member having a divided rectangular wire structure in which a plurality of coil wires are gathered at a high density.

-Outline of coil formation process-
FIG. 1 is a plan view showing an assembling apparatus for forming a coil member according to an embodiment of the present invention.
As shown in the figure, the divided rectangular wire 10 of this embodiment is formed by bundling four coil wires 11 into the divided rectangular wire 10. The divided rectangular wire 10 is composed of four coil wires 11 having a substantially rectangular cross section, and is formed of a flat plate shape. The coil wires 11 are electrically connected to each other at both ends. Functions as a flat wire. However, the number of the coil wires 11 is not limited to four, and may be two or more.

  Each coil wire 11 has a copper wire 12 having a substantially rectangular cross section, and a coating film 13 made of an imide resin, such as polyimide, polyamideimide, polyesterimide, etc., covering the copper wire 12. Yes. The cross-sectional dimensions of the copper wire 12 are, for example, a short side of about 0.95 mm and a long side of about 1.20 mm, and the thickness of the coating film 13 is about 0.03 mm, but is not limited thereto. Absent.

The assembling apparatus according to the present embodiment includes a winding unit 30 having four bobbins 30a to 30d around which the coil wires 11 are individually wound, and a running wrinkle correction unit for correcting the running wrinkles of each coil wire 11. 35, the coil wire 11 is assembled to form the split rectangular wire 10, and then the curl correction portion 37 that simultaneously corrects the curl of each coil wire 11, and the split rectangular wire 10 is wound in an edgewise manner to form a coil member. The winding part 40 which forms 20 is provided.
The wire rod of the coil wire 11 includes a winding rod (longitudinal curvature) mainly due to being wound around the bobbins 30a to 30d, and a lateral deformation mainly caused when the bobbins 30a to 30d are assembled into the divided rectangular wires. There is a twist. Strictly speaking, lateral twisting and deformation also occur when wound on a bobbin, but in this specification, the lateral deformation and twisting are collectively referred to as “running rod”. It is distinguished from.

  FIG. 2 is a perspective view showing an example of the structure of the unwinding portion 30. In this example, the bobbins 30a and 30b among the bobbins 30a to 30d are arranged at the same height, and the winding position of the coil wire 11 is the lower end of the bobbins 30a and 30b. On the other hand, the bobbins 30c and 30d are disposed at the same position and below the bobbins 30a and 30b, and the winding position of the coil wire 11 is the upper end position of the bobbins 30a and 30b. Thus, by arranging the four bobbins 30a to 30d in three dimensions, the difference in the horizontal position where the coil wire 11 is unwound and the difference in the height direction position can be reduced as much as possible. It is possible to suppress the occurrence of traveling soot on the line 11.

  The bobbins 30a to 30d are automatically adjusted so that the bobbins 30a to 30d are individually traversed in the vertical direction. With this configuration, even if the remaining number of the coil wires 11 in the bobbins 30a to 30d changes, the height position at which the coil wires 11 are unwound is kept substantially constant, so that the running rod of the coil wires 11 is made as small as possible. be able to. The bobbins 30a to 30d may be individually traversed in the axial direction. In that case, the running rod of the coil wire 11 can be made extremely small.

  Further, in this embodiment, a dancer roll is not used, and a photoelectric sensor arranged for each coil wire 11 is used, and the winding of the coil wire 11 from the bobbins 10a to 10d is synchronized with the winding in the winding unit 40. By doing so, the tension acting on the coil wire 11 is kept constant. In this way, the running tack in the coil wire 11 can be reduced by keeping the tension constant without using a dancer roller that is widely used in the wire processing field.

  FIG. 3 is a perspective view illustrating the configuration of the running wrinkle correction unit 35 and the curl correction unit 37. The traveling tack correction section 35 is configured by arranging a frame 34 and a traveling tack strainer 33 composed of seven rolls attached to the frame 34 for each coil wire 11. In the traveling rod strainer 33, seven grooved rolls that rotate about an axis orthogonal to the axial direction of the bobbins 30a to 30d (in this embodiment, a vertical axis) are alternately arranged on the left and right. Although not shown, the traverse direction position of each grooved roll is configured to be manually adjustable. That is, while applying tension to each coil wire 11, each coil wire 11 is forced to pass through the grooves of the seven grooved tolls, thereby individually correcting the running wrinkles of each coil wire 11.

  In addition, the curl correction unit 37 includes a frame 36 and a curl strainer 38 composed of seven rolls attached to the frame 34. In the curly strainer 38, seven grooved rolls rotating around an axis parallel to the axis of the bobbins 30a to 30d (in this embodiment, a horizontal axis) are alternately arranged up and down. Although not shown, the traverse direction position of each grooved roll is configured to be manually adjustable. Then, with the first grooved roll of the curl strainer 38, the coil wires 11 are assembled and bundled into the divided rectangular wire 10, and after that, the divided rectangular wire 10 is forcibly provided with seven grooves while applying tension. Pass the roll groove. Thereby, the curl of each coil wire 11 caused by being wound around each bobbin 10a to 10d is corrected.

  In this embodiment, the four coil wires 11 are assembled and bundled into the divided rectangular wires 10 to correct the curl, but before each coil wire 11 is assembled, the curl is individually collected. May be corrected. In that case, the curl strainer 38 is required at four locations, but this embodiment has an advantage that only one curl strainer 38 is required.

  FIGS. 4A to 4C are plan views showing the initial winding procedure of the coil in the winding unit 40. FIG. The winding portion 40 includes a frame 41 that can be rotated around the central axis O1, a central shaft member O that is fixed to the frame 41, and an arcuate guide groove that is formed on the frame 41 and that is centered on the central axis O1. 42, an engagement pin 43 engaged with the guide groove 42 and rotatable about the central axis O1, and connected to the engagement pin 43 below the frame 41, and along the groove 46 of the central axis O1. A holding roll 45 with a collar that can rotate around and a fixed guide 47 that guides the divided rectangular wire 10 from both sides are provided. The fixed guide 47 is not necessarily provided, but by providing the fixed guide 47, it is possible to reliably prevent the divided rectangular wire 10 from being separated.

  FIG. 6 is a cross-sectional view showing a gripping state of the divided rectangular wire 10 by the holding roll 45. The restraining roll 45 restrains the upper surface of the divided rectangular wire 10 at the brim portion and restrains the end face of the divided rectangular wire 10 at the small diameter portion 45a. The divided rectangular wire 10 is bent along the cylindrical body of the central shaft member O. Then, as shown in FIG. 4A, when the divided rectangular wire 10 is sent from the curl strainer 38 side, the divided rectangular wire 10 is sandwiched between the frame 41 and the flange portion of the holding roll 45, and the holding roll. The end face of the divided rectangular wire 10 is constrained by the 45 small diameter portion 45a.

  As shown in FIG. 4B, the frame 41, the engagement pin 43, the guide groove 42, the holding roll 45 and the guide groove 46 are rotated around the central shaft member O in the clockwise direction. Further, each of the bobbins 30a to 30d, the traveling rod strainer 33, and the curly rod strainer 38 rotate in synchronization with this rotation operation. Thereby, the divided rectangular wire 10 is bent in an edgewise shape. At this time, when the restraining roll 45 rotates around the center axis O1, the divided rectangular wire 10 is bent with the radius of the cylindrical body of the center axis member O as the radius of curvature. Further, the divided rectangular wire 10 is always restrained from both sides by the fixed guide 47. During the bending operation, the coil wire 11 on the inner peripheral side is subjected to stress in the direction in which the thickness increases (expands) in the divided rectangular wire 10, while the coil wire 11 on the outer peripheral side decreases (can be reduced). Although the stress is applied in the direction, the entire shape is accurately maintained by restricting the divided rectangular wire 10 from the thickness direction and the width direction.

  When the bending operation is finished, the frame 41 remains stationary, and only the holding roll 45 and the engagement pin 43 are once rotated counterclockwise to press the outer periphery of the corner of the divided rectangular wire 10 around. By doing so, it is possible to ensure the bending deformation of the divided rectangular wire 10 and then return to the state shown in FIG. Thereby, springback can be further suppressed.

  During the above-described bending operation, the divided rectangular wire 10 is bent so that the bending angle exceeds 90 °. As a result, the spring back is reduced, and the angle of the corner portion of the divided rectangular wire 10 becomes approximately 90 ° even if the spring back is somewhat.

  Next, when bending of one corner is completed, the frame 41, the guide groove 42, the holding roll 45, and the guide groove 46 are rotated counterclockwise around the central shaft member O as shown in FIG. When moved, the frame 41 and the like return to the initial positions shown in FIG. In this state, the frame 41, the guide groove 42, the holding roll 45, and the guide groove 46 remain stationary, and the bobbins 30a to 30d, the running rod strainer 33, and the winding rod strainer 38 are rotated, and the divided rectangular wire 10 is coiled. Sends forward by the short side length of the member.

  Thereafter, the above operation is repeated to bend the four corners. At this time, the wound divided rectangular wire 10 rides on the restraining roll 45 from the tapered portion on the outer periphery of the restraining roll 45.

FIGS. 5A to 5C are plan views showing a procedure in which the divided rectangular wire 10 is wound many times and the coil member 20 is formed after the first winding is completed.
As shown in FIG. 5A, when the split rectangular wire 10 is fed forward by the long side length of the coil member 20 from the curl strainer 38 side, the jig 48 is set and the short side of the coil member 20 is set. Part is sandwiched.

  Then, as shown in FIG. 5B, while the frame 41, the guide groove 42, the holding roll 45, and the guide groove 46 rotate and the divided rectangular wire 10 is bent, the coil member 20 is clamped by the sandwiching jig 48. The short side is fixed. In this way, by fixing the coil member 20 with the sandwiching jig 48 during the bending operation, the entire shape of the coil member can be finished in accordance with the set shape.

Similarly, as shown in FIG. 5C, the long side portion of the coil member 20 is fixed by another clamping jig 49 during the bending operation when the next corner portion is formed.
The coil member 20 wound by a predetermined number of times is formed by repeating the above operation.

FIG. 7 is a perspective view showing structures of the coil member 20 and the split core 51 according to the embodiment. In FIG. 7, the divided rectangular wire 10 is displayed as one rectangular wire, but has a structure in which four coil wires are assembled as described above. The coil wires 11 are electrically connected to each other at the two terminals 21 and 22 at both ends.
Further, the coil member 20 is molded by a resin indicated by a broken line in the drawing except for the two terminals 21 and 22, and is a so-called cassette coil.

  The split core 51 has a yoke part 51a and a tooth part 51b. In this embodiment, although the powder core structure is employ | adopted, you may use a laminated steel plate. In the case of a powder compact structure, the broken line portions shown in FIG.

  The broken line shown in FIG. 7 has shown the external shape of resin which has molded the division | segmentation rectangular wire 10 of the coil member 20. FIG. The mold resin is provided with portions that fit into the upper surface and the lower surface of the yoke portion 51 a of the split core 51. Then, the coil member 20 is attached so as to surround the teeth portion 51b by fitting the mold resin into the teeth portion 51b and sandwiching the upper and lower surfaces of the yoke portion 51a.

  FIG. 8 is a sectional view showing a schematic structure of the stator 50 of the motor in the present embodiment. In FIG. 8, the display of the mold resin is omitted for easy viewing. As shown in FIG. 8, the stator 50 is assembled by enclosing a plurality of divided cores 51 from the outside by using a ring member or the like (not shown) after being combined in an annular shape. In the present embodiment, a core in which the split cores 51 are assembled is used as the core, but the core may be integrated without being split.

  A rotor (not shown) provided with permanent magnets is disposed inside the stator 50. The split core 51 has a yoke part 51a and a teeth part 51b protruding from the yoke part 51a toward the rotor. In this embodiment, the split core 51 is formed by compression molding magnetic powder having an insulating film. However, a large number of silicon steel plates may be laminated with a resin insulating layer interposed therebetween.

  And the coil member 20 as a resin-molded cassette coil is set on the teeth 51b of the split core 51. In addition, the insulator which coat | covers the teeth part 51b is unnecessary because the coil member 20 is resin-molded.

According to the method for forming a coil member of the present embodiment, while adopting a divided rectangular wire 10 structure in which a plurality of coil wires 11 are assembled, in the traveling rod correction section 35, the traveling rod strainer 33 causes each coil wire 11 to Since the traveling rods are individually corrected and then assembled as the divided rectangular wires 10, the gap generated by the traveling rods between the coil wires 11 in the divided rectangular wires 10 can be reduced as much as possible. Further, since the curl generated in the bobbins 30a to 30d is corrected by the curl strainer 38, the gap in the divided rectangular wire 10 due to the vertical curvature and the variation in the curvature can be reduced as much as possible. .
That is, the coil member 20 wound with high density can be obtained by reducing the gap between the coil wires 11 in the divided rectangular wire 10 as much as possible.

  In this case, the curl correction may be performed before being assembled to the divided rectangular wire 10, but as in the present embodiment, the coil wire 11 is collected by the curly strainer 38 after being assembled to the divided rectangular wire 10. The process can be simplified by correcting the curl simultaneously.

  And in each bobbin 30a-30d, the position in the traverse direction is adjusted individually, and the position where the coil wire 11 is unwound is kept substantially constant, so that the traveling rod of the coil wire 11 can be made as small as possible. .

  Further, when the split rectangular wire 10 is bent, it is bent beyond the set bending angle (90 ° in the present embodiment), so even if it is spring-backed, the deviation from the set bending angle can be made as small as possible.

In addition, the following effects are acquired by the structure of the division | segmentation rectangular wire 10. FIG. When the coil current frequency is f, the coil wire width is d, the magnetic flux density amplitude is Bmax, and the resistivity of the coil material is ρ, the coil vortex loss w is expressed by the following equation (1).
w = π ² f ² d ² Bmax ² / 6ρ (1)
Represented by
As an example, a rectangular wire having a cross-sectional dimension with a short side of 0.95 mm and a long side of 4.79 mm, and this is divided into four, and each coil wire 11 has a short side of 0.95 mm and a long side of 1.20 mm. The divided rectangular wire 10 of this embodiment having a cross-sectional dimension of When the coil vortex loss w of the conventional rectangular wire is 100, the coil vortex loss w of the present embodiment is 25. That is, the coil vortex loss w can be reduced to ¼.
When the coil vortex loss w of the conventional rectangular wire is 100, the coil vortex loss w of the divided rectangular wire divided into two is 50, and the coil vortex loss w of the divided rectangular wire divided into three is 33.

  In the case of the cross-sectional dimensions described above, the aspect ratio (long side / short side) of the flat wire 60 is 5.2, and the aspect ratio of each coil wire 11 of the present embodiment is 1.3. By reducing the aspect ratio, the coil wire 11 can be easily drawn, so that the manufacturing cost can be reduced.

The coil member of the present invention can also be applied to a structure in which the divided rectangular wire 10 is wound in parallel to the surface of the teeth portion of the core. However, when the edgewise coil structure is adopted as in the present embodiment Furthermore, the following effects can be exhibited.
9A and 9B are cross-sectional views when the coil member 20 having the divided rectangular wire 10 according to the present invention is attached to the tooth portion 51b and the coil member 60 having the conventional rectangular wire 61 in order. It is sectional drawing at the time of attaching to the part 51b.

In the case of the divided rectangular wire 10 of this embodiment, the radius of curvature r1 of coil bending (approximately equal to the outer radius of the cylindrical body 47c shown in FIG. 6) can be made smaller than the radius of curvature r4 of coil bending of the conventional rectangular wire 61. Therefore, the gap Sp1 on the coil end side between the split core 51b and the split rectangular wire 10 can be reduced more than the gap Sp2 on the coil end side between the split core 51b and the flat wire 61. As a result, the axial dimension (motor shaft length) of the core 50 can be reduced, and downsizing can be achieved.
In addition, since the coil length can be shortened, the manufacturing cost can be reduced by reducing the copper wire material.

(Other embodiments)
In the above embodiment, the divided rectangular wire 10 is bent at 90 ° to form the coil member 20 wound in a rectangular shape. However, in the present invention, the divided rectangular wire 10 is bent at an angle different from 90 °. The present invention can also be applied to the formation of a coil member wound in a shape such as a parallelogram or a rhombus. Alternatively, the coil member wound in a circular shape may be formed by continuing to bend with a certain radius.

  In the above embodiment, the lengths of the long side and the short side of each divided rectangular wire 10 in the coil member 20 are made constant, but the lengths of the long side and the short side are changed, for example, for each turn. Therefore, it is possible to form a shape in which a frustum-shaped core is wound.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  In the above-described embodiment, the structure in which the core 50 is divided into a large number of divided cores 51 is adopted, but a plurality of divided cores 51 may be integrated.

  The coil member forming method of the present invention can be used for motors (including linear motors), generators, reactors, transformers, etc. disposed in industrial motors, hybrid vehicles, electric vehicles, fuel cell vehicles, robots, and the like. it can.

It is a top view which shows the assembly apparatus for forming the coil member which concerns on embodiment of this invention. It is a perspective view of the unwinding part in an embodiment. It is a perspective view of a running wrinkle correction part and a curl wrinkle correction part in an embodiment. (A)-(c) is a top view which shows the initial winding procedure of the coil in a winding part. (A)-(c) is a top view which shows the procedure in which the division | segmentation rectangular wire is wound many times and the coil member is formed after the first 1 winding is complete | finished. It is sectional drawing which shows the holding | grip state of the division | segmentation rectangular wire by a control roll. It is a perspective view which shows the structure of the coil member which concerns on embodiment, and a division | segmentation core. It is sectional drawing which shows the schematic structure of the stator 50 of the motor in embodiment. (A), (b) is sectional drawing at the time of attaching the coil member of this invention to a teeth part in order, and sectional drawing at the time of attaching the conventional coil member to a teeth part.

Explanation of symbols

O central shaft member O1 central shaft 10 split rectangular wire 11 coil wire 12 copper wire 13 coating film 20 coil member 21, 22 terminal 30 unwinding portion 30a to 30d bobbin 33 traveling rod strainer 34 frame 35 traveling rod correction unit 36 frame 37 Curly Wrinkle Correction Unit 38 Curly Wrinkle Strainer 40 Winding Portion 41 Frame 42 Guide Groove 43 Engaging Pin 45 Retaining Roll 46 Guide Groove 47 Fixed Guide 50 Core 51 Divided Core 51a Yoke Part 51b Teeth Part

Claims (6)

A step (a) of unwinding the plurality of coil wires from a bobbin wound with a plurality of coil wires having a rectangular cross section;
A step (b) of correcting wire wrinkles of the plurality of coil wires that have been unwound; and
A step (c) of assembling the plurality of coil wires into divided rectangular wires;
After the steps (b) and (c), a step (d) of winding the divided rectangular wire into a shape surrounding the core;
The formation method of the coil member containing this. In the formation method of the coil member according to claim 1,
In the step (b), the running wrinkles of the plurality of coil wires are individually corrected before the step (c), while the winding wrinkles of the respective coil wires in the divided rectangular wires after the step (c). A method of forming a coil member that simultaneously corrects. In the formation method of the coil member according to claim 1 or 2,
In the step (d), the divided rectangular wire is bent in an edgewise shape and wound in a shape surrounding the core in an edgewise shape. In the formation method of the coil member according to any one of claims 1 to 3,
In the step (a), a coil member forming method using a plurality of bobbins that are individually traversable as the bobbin. In the formation method of the coil member according to any one of claims 1 to 4,
In the step (d), a method for forming a coil member, wherein the divided rectangular wire is bent to an angle exceeding a set bending angle. In the formation method of the coil member according to any one of claims 1 to 5,
A method for forming a coil member, further comprising a step of molding the wound divided rectangular wire with a resin after the step (d).

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