JP2012039805A - Method for manufacturing coreless armature - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a coreless armature, which can easily manufacture the coreless armature.SOLUTION: In the method for manufacturing the coreless armature, which forms a coil substrate body 9 by concentrically overlapping a cylindrical coil substrate 1 having many conductive bands 3 formed thereon in parallel through an insulation layer 13, and overlaps and joins terminal parts 5 of the conductive bands 3 of each coil substrate 1, the method for manufacturing the coreless armature includes cutting a side edge part 7 from the conductive bands 3 by cutting with a laser or a gas from the outer periphery of the coil substrate body 9, and also joining the overlapped terminal parts 5 of the each conductive band with dross 19 produced by the laser cutting or gas cutting.

Description

  The present invention relates to a method for manufacturing a coreless armature used as a rotor of a generator or a motor.

  In Patent Document 1, a coil substrate body is formed by concentrically stacking a coil substrate in which a large number of conductive bands are formed in parallel via an insulating layer, and then, in each coil substrate, ends of conductive bands adjacent in the circumferential direction. It is disclosed that the side edge portion connecting the portions is removed by cold forming, and then the end portions of the overlapping conductive bands are connected by soldering, laser welding or the like.

  Although there is no specific description about the removal means by cold forming in patent document 1, generally it was cut with a cutting blade or the like.

Japanese translation of PCT publication No. 2002-542749

  However, in the prior art, after cutting the side edge, the ends of the conductive bands overlapped in the radial direction are connected by laser welding or the like, and the side edge cutting step and the conductive band end connecting step Since the two processes are separated, there is a problem that it takes time to manufacture.

  Then, an object of this invention is to provide the manufacturing method of the coreless armature which can manufacture a coreless armature easily.

  According to the first aspect of the present invention, a coil substrate body is formed by concentrically stacking a cylindrical coil substrate in which a large number of conductive bands are formed in parallel via an insulating layer, and ends of the conductive bands of each coil substrate. In the method of manufacturing a coreless armature that overlaps and joins each coil substrate, each coil substrate has a side edge portion that connects the end portions of adjacent conductive bands in the circumferential direction, and laser cutting or gas is applied from the outer periphery of the coil substrate body. The coreless armature manufacturing method is characterized in that the side edge portion is cut from the conductive band by cutting, and the end portions of the respective conductive bands are joined by dross generated by laser cutting or gas cutting.

  According to a second aspect of the present invention, in the first aspect of the invention, the assist gas is blown to a cutting portion by laser cutting or gas cutting, and the assist gas is directed from the outer peripheral side to the inner peripheral side of the coil substrate body. It is characterized by blowing and guiding the flow of dross.

  According to the first aspect of the present invention, the side edge portion is cut from the conductive band by laser cutting or gas cutting, and at the same time, the end of the conductive band (hereinafter referred to as “terminal”) is overlapped by laser cutting or gas cutting. It can be connected by the generated dross. Therefore, since the side edge portion is cut and the terminal is welded simultaneously, the coreless armature can be easily manufactured.

  According to the second aspect of the present invention, the effects described in the first aspect can be achieved and the dross can be guided by the assist gas in the terminal overlapping direction and can be placed on the end face of the terminal overlapped. Can be carried out easily and reliably.

It is a figure which shows the manufacturing method of the coreless armature which concerns on embodiment of this invention, (a) is a perspective view, (b) is the top view which looked at the coil board | substrate body from the radial direction outer side. It is a perspective view which shows the end surface of the terminal layer after cut | disconnecting a side edge part. It is a longitudinal cross-sectional view of the coil board | substrate body after cut | disconnecting a side edge part. It is a perspective view which expands and shows a coil substrate. It is a disassembled perspective view which shows the state which has arrange | positioned the coil board | substrate concentrically.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, the first embodiment will be described. The coreless armature according to the first embodiment is used as a rotor of a generator.

  As shown in FIG. 4, a large number of conductive bands 3 are formed in parallel on the coil substrate 1 at intervals, and each terminal 5 of each conductive band 3 is connected by a side edge portion 7. The coil substrate 1 has conductive bands 3 formed on a copper plate or an aluminum plate at intervals by etching or pressing.

As shown in FIG. 5, the coil substrate 1 has a cylindrical shape and is arranged concentrically to form a cylindrical coil substrate body 9. Therefore, in the coil substrate body 9, the side edge portions 7 of the respective coil substrates 1 and the terminals 5 of the conductive band 3 are arranged so as to overlap in the radial direction.
As shown in FIGS. 3 and 5, an insulating resin material 13 is interposed between the coil substrates 1, and the concentric coil substrates 1 and 1 adjacent in the radial direction are insulated. In the present embodiment, four coil substrates 1 are concentrically arranged in four layers. Incidentally, the insulating resin material 13 is not provided in the portion of the terminal 5 of the conductive band 3.

Next, the laser cutting device 11 will be described. As shown in FIG. 1, the laser cutting device 11 includes a laser irradiation unit 15 that irradiates a laser, and an assist gas injection nozzle 17. The laser irradiated from the laser irradiation unit 15 can be a YAG laser or SHG laser, and the output is about 200 W, for example.
The assist gas is, for example, nitrogen gas or argon gas, and oxygen gas is used as necessary.

Next, a method for cutting the side edge portion 7 and connecting the overlapped terminals 5 in the present embodiment will be described. As shown in FIG. 1A, in a cylindrical coil substrate body 9, an assist gas is injected from an assist gas injection nozzle 17 while irradiating a laser from a laser irradiation unit 15 to a terminal 5 portion of the conductor 3. Then, the portions of the terminals 5 of the respective conductive bands 3 arranged in the circumferential direction are sequentially cut while rotating the coil substrate body 9.
As shown by the one-dot chain line in FIG. 1B, the side edge portion 7 of the conductive band 3 is formed by irradiating and cutting the end portion of the coil substrate body 9 with a laser as shown in FIGS. Disconnect from terminal 5. At that time, the assist gas controls so that at least a part of the dross 19 generated by the laser irradiation remains. When the side edge portion 7 is cut off, the dross 19 generated by laser irradiation and remaining in the assist gas jet flows through the end face of the laminated terminal 5 and is deposited on the entire end face of the laminated terminal 5. Connect.

  According to the first embodiment, the side edge 7 is cut from the conductive band 3 by irradiating a laser, and at the same time, the terminals 5 overlapped by the dross 19 generated by the laser irradiation can be connected. Therefore, since the cutting of the side edge portion 7 and the connection of the stacked terminals 5 are simultaneously performed, the coreless armature can be easily manufactured.

  Further, the dross 19 can be guided by the assist gas in the overlapping direction of the terminals 5 and placed on the end face of the overlapping terminals 5, and the overlapping terminals 5 can be connected easily and reliably.

  Next, a second embodiment will be described. In the manufacturing method of the coreless armature according to the second embodiment, the side edge portion 7 is cut from the conductive band 3 by gas cutting using acetylene gas, oxygen or the like, instead of the laser in the first embodiment. is there. According to the second embodiment, the same effects as those of the first embodiment described above can be obtained, and a larger amount of heat (output) than laser cutting can be obtained by gas cutting. This is effective when manufacturing an armature.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the present invention. For example, the assist gas may not be used at the time of cutting the side edge 7 by laser cutting or gas cutting and connecting the terminal 5.
The coil substrate body 9 is not limited to the coil substrate 1 being stacked in four layers, and may be two layers, three layers, or five layers, and the number is not limited as long as it is stacked in a plurality of layers.

DESCRIPTION OF SYMBOLS 1 Coil board | substrate 3 Conductive band 5 Terminal 7 Side edge part 9 Coil board | substrate body 15 Laser irradiation part 17 Assist gas injection nozzle 19 Dross

Claims (2)

A coreless armature in which a cylindrical coil substrate having a large number of conductive bands formed in parallel is concentrically stacked via an insulating layer to form a coil substrate body, and the ends of the conductive bands of each coil substrate are overlapped and joined. In the manufacturing method,
Each coil substrate has a side edge that connects the ends of adjacent conductive bands in the circumferential direction, and the side edge is cut from the conductive band by laser cutting or gas cutting from the outer periphery of the coil substrate body and overlapped. A coreless armature manufacturing method, wherein ends of each conductive band are joined by dross generated by laser cutting or gas cutting.   Manufacturing of a coreless armature characterized in that assist gas is blown to a cutting portion by laser cutting or gas cutting, and the assist gas is blown from the outer peripheral side to the inner peripheral side of the coil substrate body to guide the flow of dross. Method.

Images