JP2011182481A - Device for inspection of insulating layer property of enameled wire, and apparatus of manufacturing coil for rotary electric machine with the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a device for inspection of insulating layer properties of the cover of a wire rod to be used for a coil for a rotary electric machine, especially, an inspection device, which can estimate the property of an insulating layer by measuring the mechanical property of an enameled wire, and to provide an apparatus for manufacturing the coil for the rotating machine, which is equipped with the inspection device. <P>SOLUTION: The device for inspecting the slipperiness of an enameled wire is provided with a friction body which can load a testing enameled wire sent out from a sender with a dynamic frictional resistance and an evaluation mechanism which evaluates the slipperiness of the enameled wire from a change in the loaded dynamic frictional resistance. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an inspection apparatus for inspecting the insulating layer characteristics of enameled wire coating of a wire used for a coil for a rotating machine, and in particular, it can estimate the insulating layer characteristics by measuring the mechanical properties of the enameled wire coating. The present invention relates to an inspection apparatus and a manufacturing apparatus for a coil for a rotating machine including the inspection apparatus.

  Enamel wire is widely used as a magnet wire for electrical equipment. This enameled wire becomes an electric device coil by manual winding or mechanical winding. In recent years, winding by manual winding is rare, and high-speed winding is performed by a high-speed winding machine. In high-speed winding machines, enameled wire is required to have excellent slipperiness. The slip property of enameled wire is evaluated by measuring the coefficient of static friction or the coefficient of dynamic friction.

  As the static friction coefficient test method for enameled wires, the inclined static friction coefficient test method and the Howell static friction coefficient test method are widely used. In the inclined static friction coefficient test method, an enameled wire is set on a fixed-side enameled wire setting jig, an enameled wire is set on a moving-side enameled wire setting jig, cross these, and a load is placed thereon. Then, the constant speed moving table with the load cell is pulled at an appropriate speed, and the slipping property of the enameled wire is evaluated by the change in tension at that time.

  Howell's static friction coefficient test method is to stretch one enamel wire in the transverse direction and hang the other enamel wire in the longitudinal direction so as to contact one enamel wire in the transverse direction. The coefficient of static friction is obtained from the properties. On the other hand, as a dynamic friction coefficient measuring device for enameled wire, a dynamic friction coefficient measuring device of Heidon Co., etc. is commercially available.

  In addition, in a conventional vehicle AC generator, an insulating resin such as an unsaturated polyester resin or a polyester resin added with an epoxy resin is impregnated in a coil portion formed by winding an enamel wire around a stator core or a rotor core. The insulation of the coil part was improved. For example, Patent Document 1 discloses an insulating structure of a coil portion using an enameled wire with an enamel coating having a polyamideimide resin layer and using an epoxy-modified polyesterimide resin as an insulating resin.

  Furthermore, an enameled wire is fixed and formed for the purpose of protecting the coil from electromagnetic excitation force applied to the coil and environmental load, and facilitating heat dissipation of Joule heat from the coil. As a method for manufacturing such a coil, methods such as self-bonding enameled wire, integral molding, and varnish treatment may be mentioned. Of these, self-bonding enameled wires are used in many devices in that they do not require large equipment such as varnish furnaces and molding machines. A general enameled wire has an insulating layer baked on a conductor, whereas a self-bonding enameled wire has a heat-curable resin self-bonding layer formed on the outer periphery of the insulating layer. .

  In the method of manufacturing a coil using self-bonding enameled wire, when the self-bonding enameled wire is wound around a winding frame, the enameled wires are fixed by heating and pressing the coil and melting the self-bonding layer. . The form of the reel includes a resin part incorporated into a product and a metal jig used only in the manufacturing process. For heating the coil, methods such as blowing hot air in the winding, a heating furnace after winding, and energizing the coil are used. In the metal jig winding frame, the coil is removed from the winding frame after the completion of winding, heating, and fixing, and coil formation is completed (see, for example, Patent Document 2).

  When heating and pressurizing coils with self-bonding enameled wire, the resin material of the self-bonding layer melts and flows out from the point where the self-bonding enameled wires are in contact with each other, and the winding tension is relaxed. There is also an example in which a void is easily formed in the inside and reinforcing is performed by using a fusion agent in which a self-fusion layer is coated on an insulating material having strength (for example, see Patent Document 3).

  On the other hand, integral molding is a method in which the coil after winding is fixed by resin molding, and the outer shape of the stator / rotor and brake coil of the motor that takes advantage of the moldability and rigidity of the resin, and heat dissipation by filling the resin. It has been used to improve the performance of the utilized motor (see, for example, Patent Document 4).

JP 2005-328584 A JP-A-8-316082 JP-A-8-316023 JP-A-9-322497

  When high-speed winding is performed by a high-speed winding machine, the enameled wire passes through many wire guides of the high-speed winding machine. The enameled wire is required to have excellent slipperiness in order to make the wire guide pass smoothly and to prevent contact flaws from being generated by the wire guide. However, since the manifestation mechanism of the slip property on the surface of the enamel wire is not clear, it is difficult to supply an enamel wire having a large slip and a stable slip property.

  In the static friction coefficient test method of the inclined static friction coefficient test method and the Howell static friction coefficient test method, only the static friction coefficient can be measured, so that it is not possible to correctly evaluate the slipperiness when running an enameled wire like a high-speed winding machine at high speed. It was.

  Heidon's dynamic friction coefficient measuring device measures the dynamic friction coefficient of a relatively short enameled wire, and measures the dynamic friction coefficient of an enameled wire running at a relatively low speed, so that a high speed of 100 m / min or more. It was difficult to accurately grasp the slipperiness of a long enameled wire traveling in the longitudinal direction.

  For this reason, even when the static friction coefficient and dynamic friction coefficient measured with a conventional measuring apparatus are at the same level, the correlation with the actual winding property is often poor.

  Furthermore, a slight slip difference in the enameled wire greatly affects the winding property when the enameled wire is wound in a deformed die like the mechanical winding work of a deflection coil in a television CRT. However, it is impossible to accurately determine the quality of these using the static friction coefficient and the dynamic friction coefficient measured by a conventional measuring apparatus.

  Since an AC generator for a vehicle is exposed to high temperature and vibration for a long period of time, the insulating resin of the insulating structure of the coil portion is required to have not only the initial fixing strength but also a high fixing strength for a long period. In particular, an insulating resin coated and impregnated in a coil portion formed by winding an enameled wire around a stator core or a rotor core is required to have not only high fixing strength but also high insulation. If the adhesion between the enamel coating and the insulating resin is poor, there is a problem in that the life of the enamel coating is affected and insulation failure occurs early.

  Moreover, since the vehicle alternator is mass-produced, high productivity is required. In the enameled wire winding process, the enameled wire is bent and deformed, so that a large mechanical load is applied to the enameled wire, and the enamel coating is damaged. It was necessary to form an insulating resin having high strength against damage to the enamel coating.

  Moreover, since the epoxy-modified polyesterimide resin disclosed in Patent Document 1 has a very hard property, when the epoxy-modified polyesterimide resin is used as an insulating resin, the insulating resin and the enamel coating A large shear stress was generated between them, causing damage to the enamel coating and reducing the life of the enamel coating.

  On the other hand, in electromagnetic devices such as brakes, motors, generators, transformers, etc., enameled wires are used to protect the coils from electromagnetic excitation force applied to the coils and environmental loads, and to easily radiate Joule heat from the coils. Are fixed. For such a coil, a self-bonding enameled wire is used. A general enameled wire has an insulating layer baked on the outer periphery of the conductor, whereas a self-bonding enameled wire forms a resin self-bonding layer that can be further heat-cured on the outer periphery of the insulating layer. .

  In the method of manufacturing a coil using a self-bonding enameled wire, when the self-bonding enameled wire is wound, the enameled wires are fixed by heating and pressurizing and melting the self-bonding layer. For this reason, since the resin agent of the self-bonding layer melts and flows out from the place where the self-bonding enamel wires are in contact with each other during heating and pressurization, the winding tension is loosened and the coil shape is deformed. There is a problem that voids are formed in the resin agent of the layer and the strength tends to decrease. In order to avoid this problem of strength reduction, in addition to the self-bonding layer of the self-bonding enameled wire, a complicated adhesive is required in which a self-bonding layer is coated on an insulating material having strength, that is, a different bonding agent is used in combination. The film configuration was taken. However, it has been difficult to confirm the film structure of this complicated enameled wire and determine whether the target strength is obtained.

  In addition, in order to increase the coil space factor in high performance motors, rectangular self-bonding enameled wires may be used instead of round wires, but the corners of the rectangular wires have a surface tension and an insulating coating compared to the flat part. There is a problem that the film tends to be thin and there is a concern about the possibility of a decrease in insulation performance.

  Similarly, in order to increase the coil space factor, a self-bonding enameled wire in which a round wire is deformed to provide a flat portion parallel to the cross-sectional shape may be used, but the newly formed flat portion and the original At the boundary with the round R portion, there is a problem in that the elongation of the insulating coating is large, and there is a concern that the insulating performance may be degraded.

  On the other hand, in the case of a coil with an integral mold, the pressure at the time of molding is directly applied to the enameled wire, so the enameled wire wound around the outermost periphery is easy to move, and the enameled wire comes off the reel and the surface of the molded resin on the reel In addition, there is a problem that there is a concern that there is a possibility of damaging insulation by touching iron cores such as motors and brakes.

  The present invention has been made in view of this point, and the object of the present invention is to eliminate the drawbacks of the prior art described above, and the slip of the enamel wire that can measure the slip property of the long enamel wire with high accuracy. It is in providing a sex testing device.

  The present invention is an inspection apparatus characterized by inspecting an insulating layer characteristic of an enameled wire by measuring an interaction between a surface coating of the enameled wire sent out from a transmitter and an inspection probe. . As an interaction between the surface coating of the enameled wire and the inspection probe, at least one mechanical property is measured among frictional force, adsorption force, durability, and hardness.

  The present invention evaluates the insulating layer characteristics of enameled wire required in the manufacture of coils for rotating electrical machines by measuring the interaction between the surface coating of the enameled wire sent out from the transmitter and the inspection probe. A coil manufacturing apparatus for a rotating electrical machine, wherein a coil is manufactured through an enameled wire inspection apparatus. The insulating layer characteristic is at least one of adhesion, insulation, durability, high slipperiness, and strength. The inspection apparatus includes an alignment unit that aligns the inspection probe and the enameled wire coating surface, a measurement unit that measures an interaction between the inspection probe and the enamel coating, and measurement data. Provided with a rotating electrical machine coil inspection device comprising a determination unit that determines whether or not a required numerical value in the insulating layer characteristics of the enamel wire is within a range and a delivery unit that sends the enamel wire to the winding machine after the determination. It is characterized by.

  According to the enameled wire inspection apparatus of the present invention, it is possible to evaluate the slipperiness, strength, adhesion, durability, and insulation of the enameled wire surface coating, and the measurement speed is high and the slipperiness can be judged with high accuracy. Therefore, the correlation with the actual high-speed machine winding property is large, which is industrially useful.

It is a block diagram which shows an example of embodiment of this invention. It is a block diagram which shows the slip property test | inspection apparatus of the enameled wire of embodiment of this invention. It is a figure which shows the test result in the slipperiness of an enamel wire. It is a figure which shows an example of the coil shape which wound the enamel wire. It is a side view which shows the winding machine for direct winding coils. It is a side view explaining an enamel peeling part. It is a figure which shows the shape of the lubricant which oozed out on the surface of an enamel wire, and the friction image measured with the probe for a test | inspection.

  The gist of the present invention is to provide a friction body capable of applying a dynamic friction resistance to a test enameled wire sent out from a feeder, and an evaluation mechanism capable of evaluating the slipperiness of the enamel wire from a change in the loaded dynamic friction resistance. This is a device for inspecting slipping of enameled wire. It is characterized in that a moving frictional resistance is generated by passing an inspection probe in contact with a traveling enamel wire under load, and the amount of change in the dynamic friction resistance is derived from the twist of the inspection probe. An apparatus for inspecting slipperiness of an enameled wire characterized by determining whether the slipperiness of a wire is good or bad.

  In the present invention, the enameled wire may be any of a spherical body, an ellipsoidal body, a rectangular body, and a triangular body, and may be a ring shape, an elliptical hollow shape, a square hollow shape, a triangular hollow shape, or the like.

  The apparatus for inspecting slipperiness of enameled wire according to the present invention can accurately evaluate the slipperiness of enameled wire that matches the winding property when wound by an actual high-speed winding machine.

  FIG. 7 shows the shape of the lubricant that exudes on the surface of the enameled wire and the friction image measured by the inspection probe. The friction image refers to a torsional displacement when the inspection probe is twisted by a dynamic frictional resistance as seen by the magnitude of the displacement width when the probe is reciprocally scanned, and can be converted as a frictional force. Since the surface of the lubricant is white in the shape image and the portion is black in the friction image, the frictional force is small. The torsional displacement width is reduced by half in the upper part of the lubricant compared to other regions, and it can be determined that the slipperiness is good. As a result of comparing and examining this inspection method and the winding evaluation, the frictional force measured by this inspection method has a good correlation with the coil insertion force obtained by the winding evaluation, that is, slipperiness. From this, it can be said that this inspection method is an inspection method capable of determining whether or not the coil can be manufactured.

  Similarly, the hardness of the enameled wire surface coating is determined from the amount of deflection in the vertical direction of the inspection probe and represents the strength of the enameled wire surface coating.

  Further, the adsorption force of the enameled wire surface coating is determined from the magnitude of the fluctuation range when the inspection probe is changed from the lower direction to the upward direction, and represents the adhesion force between the enameled wire surface coating and the insulating layer.

  The durability of the enameled wire surface coating is judged from the amount of decrease in the amount of deflection in the vertical direction of the inspection probe based on repeated left and right scanning of the inspection probe. Is expressed.

  An example of the inspection apparatus and inspection method of this embodiment will be described.

  First, an example of a conventional optical lever AFM will be described.

  In the conventional AFM, a laser beam is applied to a flexible cantilever, a probe provided at the tip of the cantilever, an actuator for moving the sample in the XYZ directions, and a reflective surface provided on the back surface of the cantilever. Light source for irradiation, lens for condensing laser light to irradiate a predetermined area with laser light, two-divided light detector comprising two light receiving parts for receiving laser light reflected by the reflecting surface, actuator Control means for performing processing for obtaining the shape of the sample based on the control of the movement of the cantilever and the amount of movement of the cantilever in the Z-axis direction, display means for displaying the obtained surface shape, and an area where the shape of the given sample can be measured And an XYZ axis coarse movement stage for moving the sample in the XYZ axis direction.

  Then, the cantilever, the light source, the two-divided photodetector, and the lens are fixed to a fixed portion.

  Conventionally, the most commonly used actuator is a moving means called a tube scanner. Such a tube scanner is an actuator that is manufactured by using a material such as PZT, for example, and is divided and pasted on the outer periphery of a cylindrical tube to enable movement in the XYZ3 directions.

  Specifically, when a coordinate system is set, scanning in the X-axis direction is possible by applying voltages having the same size but different signs to one of the electrodes, and similarly, the size is applied to the other electrode. By applying voltages having the same sign but different signs, scanning in the Y-axis direction becomes possible. In addition, a common electrode is provided on the inner periphery of the tube, and the tube can be expanded and contracted in the Z direction by applying a predetermined voltage between the common electrode and all the electrodes. is there. Therefore, the tube scanner functions as an actuator that moves the sample in the X, Y, and Z3 axis directions.

  When measuring the surface physical properties of the sample placed on the actuator, the amount of movement of the actuator in each axial direction is controlled by the control means, and the probe is detected in a predetermined area on the XY plane on the sample surface. The sample is moved relative to the needle, and scanning is performed to measure the physical properties of the sample. By such scanning, the probe interacts with the sample, and the magnitude of this force causes the cantilever to bend and the probe to be displaced in the Z-axis direction, so that the amount of bending of the cantilever is constant. By scanning the sample while performing feedback control, the physical properties of the surface of the sample can be obtained corresponding to the feedback control amount. In order to make the amount of bending of the cantilever constant, the laser light emitted from the light source, condensed by the lens, irradiated on the reflecting surface of the cantilever and reflected is received by the two-divided photodetector, Control may be performed to move the sample in the Z direction by controlling the amount of movement of the actuator so that the differential outputs from the light receiving units are equal.

  The XYZ axis coarse movement stage is not an indispensable means. However, in order to move the sample in the XYZ axis direction to an area where the physical property measurement of a given sample can be performed, normally, such a means is provided. It has become.

  In addition, the optical system that constitutes a so-called “optical lever” that receives the laser light emitted from the light source, collected by the lens, irradiated by the reflecting surface of the cantilever and reflected by the two-divided photodetector. Therefore, an atomic force microscope that employs this optical system is generally referred to as an “optical lever type”. Specifically, the light beam has a reflection angle that is twice the deflection angle of the cantilever, and the laser beam is reflected from the reflection surface of the cantilever.

  There has also been proposed a microscope having a configuration in which an AFM is provided with an optical microscope for observing the state of the sample and the position of the cantilever on the sample.

  As a configuration method, an optical microscope is provided directly above the cantilever, and the sample is observed from directly above the cantilever.An optical microscope is provided obliquely with respect to the bottom surface of the fixed portion. An observation method has been proposed.

  By the way, in the conventional optical lever type AFM, a sample is placed on an actuator, and the sample itself is directly moved in the XYZ directions. When it is integrated with a winding machine or connected to an enamel wire feeder, it is necessary to make it difficult to receive vibration from these machines.

  The inspection apparatus of the present invention will be described. The inspection apparatus of the present invention includes a cantilever having a probe for measuring the shape and physical properties of a given sample, a light source, a lens for collecting light emitted from the light source, and reflection of the collected light by the cantilever. A light receiving device that receives light, a first displacing means that can fix the cantilever and move the cantilever in two orthogonal axes, and the 2 that is the moving direction of the cantilever by fixing the first displacing means. A second displacement means capable of moving the first displacement means in one axial direction perpendicular to the axial direction, a predetermined signal is given to the first and second displacement means, and the probe and the sample are The physical property of the sample is measured in accordance with the relative movement processing and the signal given to the first displacing means for setting the bending amount of the cantilever to a predetermined amount corresponding to the output from the light receiver. System to do at least processing It has a means, and display means for displaying at least the measured physical properties.

  The first displacement means is composed of a tube scanner, and the second displacement means is composed of a piezoelectric element.

  Further, a configuration in which an optical microscope and an objective lens for focusing the optical microscope on the cantilever are provided immediately above the cantilever is also conceivable.

  The inspection probe provided at the tip of the cantilever preferably has a curvature radius of 10 nanometers or more and 500 micrometers or less. Further, it is preferable that a fine movement drive mechanism is provided immediately above the inspection probe so that the inspection probe contacts the surface of the enamel wire with a constant load.

  FIG. 1 is a configuration diagram showing an example of an embodiment according to the inspection apparatus of the present invention.

  A sample 107 as a shape measurement target is placed on an XYZ stage 109 which is a sample fixing base. The XYZ stage 109 is, for example, a means for moving the sample 107 placed on the fine movement mechanism to an area where physical properties can be measured. The XYZ stage 109 is configured by using a commercially available optical movement stage. It ’s fine. In addition, although this means is not essential, it is preferable to prepare.

  The cantilever 103 having a probe at the tip is manufactured in a leaf spring shape using, for example, silicon or the like as a material. The back surface of the cantilever 103 is provided with a reflective surface that reflects light. The tube scanner 105 can realize a moving mechanism of the cantilever 103 in the X and Z directions. As the piezoelectric element 117, for example, a multilayer piezoelectric element formed by using PZT or the like as a material and arranging piezoelectric materials in a laminated form may be used. When a predetermined voltage is applied to the piezoelectric element 117 from the control circuit, pressing in the Y-axis direction occurs, and the parallel spring 115 moves in the Y-axis direction by the pressing. Therefore, the cantilever 103 provided at the tip of the tube scanner 105 provided in the parallel spring 115 moves in the Y-axis direction. Thus, by applying a predetermined amount of voltage to the piezoelectric element 117, the cantilever 103 can be moved in the Y-axis direction by a predetermined amount. That is, the movement mechanism in the Y-axis direction can be realized by the configuration having the parallel spring 115 and the piezoelectric element 117.

  The control circuit 111 is a means for performing at least the following processing, and is realized by an electronic device such as a CPU, a ROM (a program for performing a predetermined processing in advance), a RAM, and various CMOSs.

  First, a predetermined driving voltage is applied to the tube scanner 105 to move the cantilever 103 in the X and Z directions.

  Next, it is a process of transmitting a predetermined signal for moving the cantilever 103 in the Y-axis direction. Specifically, a predetermined voltage is applied to the piezoelectric element 117 as described above.

  Further, the two-divided light detector 106 receives the reflected light from the cantilever 103 and controls the amount of movement of the tube scanner 105 so that the differential outputs from the respective light receiving parts are equal, that is, the bending of the cantilever 103. A process for obtaining the surface shape of the sample 107 corresponding to the feedback control amount is performed while performing feedback control so that the amount becomes constant.

  The display device 112 has a function of displaying at least the shape information of the sample 107 detected by the control circuit 111, and is realized by, for example, a CRT, EL display, or liquid crystal display.

  The fixing unit 110 is means for fixing the light source 101, the lens 102, and the two-divided photodetector 106, and further fixing the XYZ stage 109 to the lower part thereof. For example, a metal material or the like that has been subjected to rust prevention processing may be used and designed and manufactured so as to exhibit a desired shape.

  An optical microscope 120 including an objective lens 118 for focusing on the sample 107 is fixed to the fixing unit 110, and the sample 107 can be observed from above by the optical microscope 120.

  Further, on the fine movement side of the parallel spring 115 driven by the piezoelectric element 117 (in the figure, a is the fine movement side of the parallel spring and b is the fixed side of the parallel spring), the central axis of the tube scanner 105 is It is preferable that the tube scanner 105 is fixed so as to be parallel to the sample surface, and the cantilever 103 is provided at the lower end of the tip.

  One of feedback control in the Z direction and scanning in the XY plane (generally, scanning with a higher scanning speed: when performing two-dimensional raster scanning, the scanning speed in one direction is faster and the scanning in the other direction is faster. The scanning speed is low) by the operation of the tube scanner, and the other scanning of the in-plane scanning (that is, the scanning with the slower speed) may be performed with a parallel spring.

  First, the user places the sample 107 on the XYZ stage and uses the XYZ stage 109 to move the sample 107 in a three-dimensional direction to a position where the shape of the sample 107 can be measured. Since the optical microscope 120 for observing the cantilever 103 and the sample 107 is arranged in the space immediately above the cantilever, the user can use this to properly place the sample, that is, the sample 107. It is possible to perform the setting operation of the sample 107 while confirming whether the position of the cantilever 103 is appropriate, and the operability of the device is improved.

  When the operation of the device is started, the control circuit 111 gives a predetermined signal to the tube scanner 105 and the piezoelectric element 117 as described above.

  The probe provided at the tip of the cantilever 103 starts scanning the sample 107 in the X and Y axis directions. Then, the control circuit 111 moves the tube scanner 105 in the Z-axis direction so that the differential outputs from the light receiving units corresponding to the reflected light from the cantilever 103 received by the two-split photodetector 106 become equal. The amount is controlled, that is, the surface shape of the sample 107 corresponding to the feedback control amount is obtained while performing feedback control so that the amount of bending of the cantilever is constant.

  The sample is scanned in the direction perpendicular to the cantilever, for example, in the case of frictional force. The physical properties measured by the above scanning are displayed on the display device 112, and the physical property measurement of the sample 107 is completed.

  An embodiment of the enameled wire slipperiness inspection apparatus and its evaluation method according to the present invention will be described with reference to FIG.

  The enamel wire is positioned in the alignment section so that the inspection surface is directly above. For example, in the case of a flat wire, it is determined whether the inspection surface is the edge of the corner, the center of the plane portion, or the corner of the plane portion, and the inspection probe comes to that position. Position to. The alignment unit is provided with a positioning mechanism in which a feeding line tray or a roller corresponding to the cross-sectional shape of the wire is arranged, and the inspection probe can approach the position to be measured.

  Next, an approaching probe is approached immediately above the enameled wire where the cantilever with the tip attached is positioned. A laser is applied to the cantilever surface. The change amount of the cantilever is detected from the detector. From this result, it is determined whether the winding is OK or NG. The sending unit determines whether or not to send the enameled wire based on the determination.

  Next, an example of the inspection on the slipperiness of the enameled wire will be shown. FIG. 3 shows the test results.

  As a result of comparing and examining this inspection method and the winding evaluation, the frictional force measured by this inspection method has a good correlation with the coil insertion force obtained by the winding evaluation, that is, slipperiness. From this, it can be said that this inspection method is an inspection method capable of determining whether or not the coil can be manufactured.

  In addition, the enameled wire slipperiness inspection device of the present invention is capable of long-slip evaluation, has a high measurement speed, has a wide selection of enamelled wires, and can determine slippery accuracy with high accuracy. Therefore, the correlation with the actual high-speed machine winding property is large.

Next, a thermal endurance test of an AC generator for a vehicle incorporating a stator 10 to which an enameled wire whose insulation property was determined to be OK was incorporated was performed using this inspection apparatus. In this thermal endurance test, the vehicle AC generator was operated for a long time under the following conditions, and the time until power generation failure was measured.
(1) Generator rotation speed: 3000rpm (constant)
(2) Atmospheric temperature: 120 ° C
(3) Electric load and time: repetition of battery load (power generation output about 5A) × 30min and maximum load (power generation output about 70A) × 30min

  The power generation failure is caused by a decrease in generated current due to a short circuit between the stator coils caused by deterioration of the enamel coating, and the insulation of the stator coil (enameled wire) can be compared.

  As a result of comparing the NG enameled wire and the OK enameled wire with this inspection device, it was confirmed that a life of 2.4 to 3.2 times was obtained.

  In an AC generator for a vehicle, it is necessary to endure use for a long period of time, for example, 15 years, 150,000 km, and the insulation structure of the stator coil portion applied thereto has not only a high initial fixing force. Therefore, it is required to maintain a high fixing force over a long period of time. The coil manufactured according to the first embodiment can maintain such a high adhering force and excellent insulation over a long period of time, and is optimal for a stator coil of a vehicular AC generator.

  A coil used for a circuit breaker, a relay or the like is formed by winding an enameled wire having a wire diameter of about 1 mm or more as shown in FIG. 4a and peeling off the enamel at both ends, as shown in FIG. 4b. There is a bobbin winding coil 5 in which an enameled wire having a wire diameter of about 1 mm or less is wound around a plastic bobbin 3 and both ends are tangled to a terminal 4 and then joined together. There are many commercially available special winding machines for different bobbin shapes.

  FIG. 5 is a side view showing a commercially available general winding machine for a series winding coil. This winding machine includes a winding section 6, a base base 7, a wire cutting section 8, a wire supply section 9, and an enamel peeling section 10. , Wire rod storage unit 11 and control unit 12.

  First, the winding portion 6 rotates and positions the winding core 13 for winding the enameled wire, the holding plate 14 attached to the side surface of the winding core 13 to hold the tip of the enameled wire, and the winding core 13. A rotary positioning mechanism 15 comprising a bearing box for support, a drive motor and a shaft coupling (not shown), and a linear guide for support, a ball screw, and a drive for positioning the rotary positioning mechanism 15 in the vertical direction. Uniaxial positioning mechanism 16 comprising a motor and a shaft coupling (not shown), a receiving cylinder 17 having a hole slightly larger than the winding core 13 and rotatably supported by a bearing, and the receiving cylinder 17 as a winding core. 13 and a receiving cylinder up-and-down mechanism 18 that is moved up and down by an air cylinder in the lower direction in the coaxial direction.

  The wire cutting unit 8 is a wire guide having a hole with an inner diameter slightly larger than the wire diameter of the enameled wire 1 so that the gap with the wire is made as small as possible when the wire supply unit 9 sends out the enameled wire as much as possible. 19 and a cutting and bending blade 20 and a receiving blade 21 for bending the end of the enamel wire 1 near the exit of the wire guide 19, and both the blades 20 and 21 are vertically moved by an air cylinder (not shown). A blade up-and-down mechanism 22 that reciprocates, and a tip bending blade 23 and a tip receiving blade 24 that can be moved up and down by an air cylinder to bend the tip of the enamel wire in front of the core 13 when viewed from the outlet of the wire guide 19.

  The wire supply unit 9 includes a pair of rollers 25 and 26 having grooves so that enamel wires are sandwiched on the outer periphery, and a support bearing box, a driving motor and a shaft for rotationally positioning one of these rollers 25. A roller rotation positioning mechanism 27 made of a joint (not shown) and fixed on the base table 7 and a bearing box supporting the other roller 26 are reciprocated in the horizontal direction by an air cylinder to wrap the enamel wire 1. A roller opening / closing mechanism 28 for opening and closing the roller 26 with respect to the roller 25 is provided.

  Next, as shown in FIG. 6, the enamel peeling portion 10 includes a hollow rotary shaft 31 that is rotatably supported by a bearing base 30 having a pair of bearings 29, and an enamel wire attached to the tip of the rotary shaft 31. Is supported so as to be able to rotate around a pair of pins 33 which are rotated together with the rotary shaft 31 and are mounted near the tip of the rotary shaft 31. A pair of blocks 34, a pair of blades 35, 36 mounted so as to rotate together with the block 34 and adjust the position relative to the block 34 with screws, A hollow sliding shaft 38 having a pressing pin 37 that pushes the block 34 at the tip is supported by a key on the outer periphery so as to be slidable in the axial direction, and the hollow sliding shaft 39 via a thrust bearing 39. An air cylinder 40 that slides the hollow sliding shaft 38 by pushing the inner surface of the shaft 38, and a stopper 41 that determines the operating position of the air cylinder 40 so that the distance between the pair of blades 35 and 36 is the same as the peeling diameter. The motor 42 for rotating the rotary shaft 31, a belt 43, and a pulley 44 are included.

  Furthermore, the wire rod storage unit 11 is provided with a plurality of correction rollers 45 provided with grooves so as to sandwich the enamel wire on the outer periphery and rotatably supported, and a gap of about the diameter of the wire to correct the bending of the enamel wire. In this way, two sets of strainers 46, in which two rollers 45 are arranged in parallel in two rows, are fixed on the base 7 so as to be in two horizontal and vertical directions, and a wire drum 47 supplied from an electric wire manufacturer is rotated. In order to support freely and reduce fluctuations in tension, a storage base 49 configured to suspend the enamel wire with a series of springs 48 is provided. Moreover, the base stand 7 is provided with the discharge port 50 which discharges | emits the completed coil other than arrange | positioning said each part.

  The conventional winding machine is configured as described above, and its operation is as follows. The enameled wire that has been manually inserted in advance from the wire rod storage unit 11 to the wire guide 19 is sandwiched between the rollers 25 and 26 by the roller opening / closing mechanism 28 and then fed out by a predetermined amount by the roller rotation positioning mechanism 27. Next, when the tip bending blade 23 rises and the tip of the enamel wire is bent with respect to the tip receiving blade 24, the enamel wire is pulled back to a position where the tip hits the holding plate 14 by the wire rod supply unit 9. Then, the rotational positioning mechanism 15 and the single-axis positioning mechanism 16 immediately start positioning control of the rotation amount and the vertical amount, and the enamel wire is wound around the core 13 because the tip of the enamel wire is caught by the holding plate 14. On the way, when the winding is turned back (for example, turned back from the first layer to the second layer), the cylinder lifting mechanism 18 raises the receiving cylinder 17 and presses it against the lower surface of the coil, and the enamel wire is folded at a desired position.

  Moreover, enamel peeling of both ends of the coil is performed as follows. In the enamel peeling portion 10, when the air cylinder 40 is operated to the position of the stopper 41 at an appropriate timing in the winding, the hollow sliding shaft 38 is pushed on the inner surface via the thrust bearing 39 to the rotating shaft 31. The pair of blocks 34 rotate around the pins 33 through the pressing pins 37. In this way, the pair of blades 35, 36 rotate together with the rotary shaft 31 and bite into the enamel wire to cut the enamel, and the enamel wire is peeled off while passing through the rotary shaft 31, the inner hole, and the line guide 32. . When the required length is peeled off, the air cylinder 40 returns to its original position, and the blades 35 and 36 are separated from the enamel wire by the reverse operation to complete the peeling. It should be noted that the timing of starting and ending the peeling is determined by the winding end of the coil wound next to the winding end terminal of the coil that has been wound with the cut and bent blade 20 sandwiched between the cutting and bending blades 20 at the time of cutting after completion of winding. It is determined in advance to be within the range of the terminal.

  When the winding is thus completed, the blade up-and-down mechanism 22 operates the cutting and bending blade 20 and the receiving blade 21 to cut and bend the winding end terminal, and then the blade up-and-down mechanism 22 is cut into the cutting and bending blade 20 and the receiving blade 21. , The coil is detached from the core 13 and dropped, and is discharged from the discharge port 50. Thereafter, if the up and down operation is repeated, the coils are wound sequentially.

  In addition, instead of the rollers 25 and 26 described above, the enamel wire is sandwiched in the wire supply unit 9 of the other series coil winding machine with a gripper having the same groove, and the gripper itself in the feeding direction. There is also a type of device that supplies enameled wire by going straight.

  In such a coil winding machine, the inspection device according to the present invention is arranged in front of the sending-out portion to be sent to the winding machine, so that the slipping property of the long enamel wire is highly accurate at the same time as the winding to the winding machine. It becomes possible to measure with.

  INDUSTRIAL APPLICABILITY The inspection apparatus and inspection method of the present invention can be effectively used for inspecting the insulating layer characteristics of enameled wires used in coils of electromagnetic devices such as brakes, motors, generators, and transformers.

Claims (9)

  An inspection apparatus for inspecting an insulating layer characteristic of an enameled wire by measuring an interaction between a surface coating of the enameled wire sent out from a sending machine and an inspection probe.   The mechanical property of at least one of frictional force, adsorption force, durability, and hardness is measured as an interaction between the surface coating of the enameled wire and the inspection probe. Inspection equipment.   By measuring the interaction between the surface coating of the enameled wire sent out from the transmitter and the inspection probe, the insulation layer characteristics of the enameled wire required in the manufacture of coils for rotating electrical machines are evaluated. A coil manufacturing apparatus for a rotating electrical machine, wherein a coil is manufactured through an inspection device.   4. The apparatus for manufacturing a coil for a rotating electrical machine according to claim 3, wherein the insulating layer characteristic is at least one of fixing force, insulation, durability, high slipperiness, and strength.   The inspection device according to claim 3, wherein the inspection device aligns the inspection probe and the enameled wire coating surface, and a measurement unit that measures an interaction between the inspection probe and the enamel coating. Coil inspection apparatus for a rotating electrical machine comprising a determination unit that determines whether measurement data is within a range of required numerical values in the insulating layer characteristics of enameled wire, and a sending unit that sends the enameled wire to the winding machine after the determination An apparatus for manufacturing a coil for a rotating electrical machine, comprising:   6. The alignment unit according to claim 5, wherein a feeding line tray or a roller corresponding to a cross-sectional shape of the wire is arranged, and an alignment mechanism is provided for allowing the inspection probe to approach a position to be measured. Coil manufacturing equipment for rotating electrical machines.   6. The apparatus for manufacturing a coil for a rotating electrical machine according to claim 5, wherein a cross-sectional shape of the wire rod of the enameled wire is any one of a circular shape, a hook shape, a rectangular shape, a polygonal shape, and a deformation.   6. The apparatus for manufacturing a coil for a rotating electrical machine according to claim 5, wherein a radius of curvature of the inspection probe is not less than 10 nanometers and not more than 500 microns.   6. The apparatus for manufacturing a rotating electrical machine coil according to claim 5, wherein the inspection probe comes into contact with the surface of the enamel wire with a constant load by providing a fine movement drive mechanism directly above the inspection probe.

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