JP2013223278A - Assembled conducting wire, coil using the same and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an assembled conducting wire capable of preventing peeling among conductor wires in bending work.SOLUTION: An assembled conducting wire 10 is formed by collectively and integrally arranging a plurality of conductor wires 12 having a rectangular cross section parallel to one another. The assembled conductive wire 10 also has a bent portion 20 bent for forming a coil. The conductor wires 12 arranged in an inner periphery side 22 of the bent portion 20 are formed so as to be smaller in width than the other conductor wires 12. This configuration can prevent shear stress occurring in bending work to prevent peeling among the conductor wires 12 due to the shear stress.

Description

  The present invention relates to a collective conducting wire, a coil using the collective conducting wire, and a method for manufacturing the same, and more particularly, to a structure of a collective conducting wire in which a plurality of conducting wires are bundled and configured integrally and an improvement in the manufacturing method.

  The motor has a rotor and a stator disposed around the rotor. The stator has a coil, and a rotating magnetic field is generated when a current flows through the coil. The rotor is rotated by an electromagnetic action acting between the rotating magnetic field and the rotor.

  Some conductors used in the above-described coils have a circular cross section. On the other hand, for the purpose of increasing the space factor of the coil, there is a case where a rectangular wire which is a substantially rectangular conductor wire is used instead of a conductor wire having a circular cross section. However, when a conducting wire having a rectangular cross section is used for the coil, eddy loss generated in the conducting wire is increased as compared with a conducting wire having a circular cross section. The principle of this eddy loss will be described with reference to FIG.

  A motor 100 shown in FIG. 4 includes a rotor 102 and a stator 104 disposed around the rotor 102. A plurality of permanent magnets 106 are embedded in the rotor 102 at intervals in the circumferential direction. The stator 104 includes a cylindrical yoke 108 and teeth 110 that protrude radially inward from the yoke 108 at equal intervals in the circumferential direction. A coil 112 is formed by winding a rectangular wire 114, which is a conducting wire having a rectangular cross section, around the slot 112 and the tooth 110 between the adjacent teeth 110.

  When the motor 100 is driven, when the rotor 102 rotates (Z direction), a part of the magnetic flux that should flow from the teeth 110 to the permanent magnet 106 due to the magnetic field fluctuation generated between the rotor 102 and the stator 104 is the leakage magnetic flux 116. It flows so as to wrap around the rectangular wire 114 located on the opening 118 side of the slot 112. In addition, a part of the magnetic flux flowing from the permanent magnet 106 to the tooth 110 does not flow into the tooth 110 but part of the magnetic flux flows as a leakage magnetic flux 120 to the rectangular wire 114 located on the opening 118 side.

  As described above, part of the magnetic flux that should flow directly into the teeth 110 and the permanent magnet 106 becomes the leakage magnetic flux 116 and 120, and may flow into the conducting wire located at the opening 118.

  Such leakage magnetic fluxes 116 and 120 cannot contribute to the motor torque and have been known to cause eddy loss. In addition, since the copper raw material is normally used for a conducting wire, in order to distinguish from the copper loss by generation | occurrence | production of the Joule heat at the time of an electric current flowing into conducting wire itself, the said eddy loss is hereafter described as copper eddy loss.

  As described above, from the viewpoint of improving the space factor of the coil, when a rectangular wire is used as the conducting wire, the area of the conducting wire located on the opening side of the slot, that is, the area where the leakage magnetic flux intersects is Since it is wide, the eddy loss is likely to be larger than that of a relatively small-diameter cross-section conducting wire, and there is a possibility that the motor torque performance resulting from this will be reduced. In order to prevent the reduction of motor torque performance as well as to improve the coil occupancy rate, a plurality of conductor wires having a reduced cross-section area, ie, conductor wires having a rectangular cross section, are arranged in parallel to each other. There are examples where collective conductors are used.

  The following Patent Document 1 describes a collective conductor in which a plurality of conductor wires having a rectangular cross section covered with a wire insulating film are arranged in parallel to each other. A binder is applied to the conductor strands, and the conductor strands are bonded to each other through the binder, thereby preventing the conductor strands from being separated from each other when they are collectively arranged. Further, an insulating film is provided on the outermost layer of the collective conducting wire, and the conductor wires arranged in a collective manner are bound to prevent them from being separated from each other.

JP 2010-055806 A

  As in Patent Document 1, the conductor wires are bonded to each other through an adhesive such as a binder, so that the conductor wires can be prevented from being separated from each other even after being arranged together. However, even in the case of a collective conducting wire in which conductor strands are bonded to each other in this way, when bending for use in a coil, shear stress is generated in the bent portion formed by this processing, and the conductor strands Peeling may occur.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a collective conductor, a coil using the collective conductor, and a manufacturing method thereof that can suppress peeling of conductor wires during bending without adding a new material or manufacturing process. There is.

  The present invention is a collective conducting wire in which a plurality of conductor wires having a rectangular cross section are arranged in parallel with each other, and has a bent portion bent to form a coil, and is arranged on the inner peripheral side of the bent portion. The conductor wire to be formed is characterized in that its width is smaller than the width of the other conductor wires.

  Further, when the bent portion is formed by being bent only on one side, the inner conductor wire is formed so that the width thereof is smaller than the width of the conductor wire arranged on the outer periphery side. Is preferred.

  In addition, when the bent portion is formed by bending one side and the other side, the conductor wires arranged on both sides in the width direction are formed so that the width is smaller than the width of the other conductor wires. It is preferred that

  Further, it is preferable that the assembly conducting wire is wound around the teeth of the stator.

  Further, the present invention provides an assembly conductor manufacturing method in which at least two types of conductor elements having rectangular cross-sections having different widths are arranged in parallel to each other, and the conductor wires arranged in an aggregate are bent and bent. A bending step for forming a portion, and in the placing step, the conductor strand is placed so that the width of the conductor strand that is planned to be on the inner peripheral side of the bent portion is smaller than the width of the other conductor strands. It is characterized by being.

  According to the collective conducting wire of the present invention, the coil using the collective conducting wire, and the manufacturing method thereof, it is possible to suppress peeling of the conductor wires during bending without adding a new material or manufacturing process.

It is a perspective view which shows the assembly conducting wire which concerns on this embodiment. It is an enlarged view which shows the A section of FIG. It is a perspective view which shows the assembly conducting wire which concerns on another embodiment. It is a figure which shows the principle which vortex loss generate | occur | produces in the conducting wire which forms the coil of a stator.

  Hereinafter, embodiments of a collective conducting wire, a coil using the collective conducting wire, and a manufacturing method thereof according to the present invention will be described with reference to the drawings. First, the collective conducting wire according to the present embodiment will be described with reference to FIGS. FIG. 1 is a perspective view showing a collective conducting wire according to the present embodiment, and FIG. 2 is an enlarged view showing a portion A of FIG.

  The collective conducting wire 10 has a plurality of conductor wires 12 having a rectangular cross section. The conductor wire 12 is a conductive material, for example, copper. The conductor wire 12 has an insulating film 14 that covers this surface. The insulating film 14 is an oxide film, for example. In addition, this invention is not limited to this structure, You may coat the surface of the conductor strand 12 with resin which has insulation.

  Further, as shown in the figure, the conductor wires 12 are collectively arranged in parallel with each other in 2 rows and 6 columns. The number 2 × 6 of the conductor wires 12 is an example, and the present invention is not limited to this number, and it is sufficient that the plurality of conductor wires 12 are arranged at least in the width direction W of the collective conducting wires 12. .

  An adhesive 16 is applied to the surface of each coated conductor wire 12, and the conductor wires 12 are bonded and integrated through the adhesive 16. The adhesive 16 is, for example, a binding material having heat-fusibility. The adhesive 16 may be made of an insulating resin such as an epoxy resin. In this case, it is possible to improve the insulation performance between the conductor wires 12 that are collectively arranged.

  In addition, the collective conducting wire 10 has an external insulating coating 18 that covers the conductor wires 12 that are arranged and integrated in a film shape. The external insulating film 18 has a role of serving as the outermost layer of the conductor wires 12 that are collectively arranged, and a role of binding the integrated conductor wires 12 and preventing them from being separated from each other. Have. The external insulating film 18 is a resin having an insulating property. Further, from the viewpoint of protecting the collective conducting wire 10, the external insulating coating 18 is preferably made of a heat-resistant resin, for example, a polyimide resin.

  With this configuration, the collective conducting wire 10 is used for a coil as described in the prior art, and particularly when used for a coil located on the opening 118 side shown in FIG. The crossing area can be reduced, and copper vortex loss can be reduced. In addition, the collective conducting wire 10 of this embodiment is not limited to only the coil located in the opening part 118 side shown in FIG. 4, The collective conducting wire 10 may comprise all the coils wound around the teeth 110. .

  The collective conducting wire 10 has a bent portion 20 bent to form a coil. As shown in FIG. 1, the bending portion 20 has an inner peripheral side 22 positioned inside the bending radius, an outer peripheral side 24 positioned outside the bending radius, and a side surface 26 adjacent to these. As shown in FIG. 1, the inner peripheral side 22 and the outer peripheral side 24 face each other in the width direction W.

  In the collective conducting wire 10 of the present embodiment, the conductor strand 12 on the inner peripheral side 22 is formed so that its width is smaller than the width of the conductor strand 12 on the outer peripheral side 24.

  Generally, when a conductor strand is bent, the outer peripheral region of the conductor strand extends while the inner peripheral region thereof contracts. Then, when bending the conductor wires arranged in a plurality in the width direction W, the extension in the circumferential direction of the outer peripheral side region (surface) of the conductor wires arranged on the inner peripheral side, and the conductor strand Due to the shrinkage in the circumferential direction of the inner circumferential side region (surface) of the conductor wire arranged on the outer circumferential side, a circumferential length difference occurs in this region. The greater the difference in perimeter, the greater the shear stress in that region, causing the conductor strands to peel off.

  The collective conducting wire 10 of the present embodiment has a smaller width of the conductor wire 12 disposed on the inner peripheral side 22 as described above. By reducing the width of the conductor wire 12 on the inner peripheral side 22 in this way, the elongation of the outer peripheral side 24 region of the conductor strand 12 is reduced, so that the difference in peripheral length is also reduced. As a result, the shear stress is reduced. It can suppress and peeling of conductor strands can be suppressed.

  In the collective conducting wire 10 shown in FIG. 2, the width of the conductor strands 12 for three rows from the inner peripheral side 22 is, for example, 0.3 mm, respectively, and the width of the conductor strands 12 for three rows on the outer peripheral side 24 Is, for example, 1.0 mm. According to such a configuration, the conductor strands 12 have a width of 1.0 mm, for example, arranged in four rows of 1.0 mm, and the third row from the outer peripheral side 24 as compared to the configuration of the assembly conductors having the same length in the width direction W. In the inner peripheral side 22 region of the conductor element wire 12, the circumferential length difference can be reduced to about half. That is, the shear stress in this region can be reduced to about half, and peeling of the conductor wires 12 can be reliably suppressed.

  In the present embodiment, the collective conducting wire 10 is formed such that the width of the conductor strands 12 for three rows from the inner peripheral side 22 is smaller than the width of the conductor strands 12 arranged on the outer peripheral side 24 from them. However, the present invention is not limited to the number of three rows of conductor wires 12 having a small width, which are arranged on the inner peripheral side. May be.

  Next, the manufacturing method of the assembly conducting wire 10 of this embodiment is demonstrated. First, a conductor wire 12 having a rectangular cross section is formed from a copper material, for example, a round conductor, and the conductor wire 12 is heated to oxidize the surface to form an insulating coating 14.

  Then, an epoxy resin is applied to each conductor wire 12 as an adhesive 16, and these conductor wires 12 are collectively arranged in parallel. At this time, in the width direction W, the conductor strands 12 having a small width are arranged in three rows on the inner circumferential side 22, and the conductor strands 12 having a larger width are arranged in three rows on the outer circumferential side 24. Then, the conductor wires 12 that are collectively arranged are heated to cure the adhesive 16, and the conductor wires 12 are integrated.

  The conductor wires 12 that are assembled and integrated by the adhesive 16 are bent by bending using a cored bar to form a bent portion 20. In the collective conducting wire 10 for coils, a plurality of bending portions 20 are formed, and the bending radius R thereof is, for example, 2.5 mm.

  The outer insulating coating 18 is applied to the surface of the collective conducting wire 10 on which the bent portion 20 is formed by coating such as electrodeposition or vacuum deposition, and the production of the collective conducting wire 10 used for the coil is completed.

  According to the collective conducting wire 10 and the manufacturing method of the present embodiment, the conductor at the time of bending is simply arranged by arranging the conductor element wire 12 having a small width on the inner peripheral side 22 without adding new materials or manufacturing processes. Peeling of the strands 12 can be suppressed.

  In the present embodiment, the present invention has been described with respect to the case where the conductor wire 12 having a smaller width is disposed on the inner peripheral side 22 of the bent portion 20 formed by bending one side (clockwise in FIG. 1). Is not limited to this configuration. If the conductor strand 12 with a smaller width is disposed on the inner peripheral side 22 of the bent portion 20, a configuration as shown in FIG.

  FIG. 3 is a perspective view showing a collective conducting wire 10 according to another embodiment. This collective conducting wire 10 has a bent portion 20 formed by bending on one side (clockwise in FIG. 3) and the other side (counterclockwise in FIG. 3). Thus, when the bending part 20 is bent in both directions, the conductor strand 12 arrange | positioned at the both sides of the width direction W is the width | variety of the other conductor strand 12 arrange | positioned in the center of the width direction W. It is formed to be smaller than the width. The conductor wires 12 arranged on both sides in the width direction W are positioned on the inner peripheral side 22 in each bent portion 20.

  With such a configuration, it is possible to reduce the circumferential length difference in the outer peripheral side 24 region of the conductor wires 12 in the third row from the inner peripheral side 22 during bending. That is, the shear stress in this region can be reduced, and peeling of the conductor strands 12 can be reliably suppressed.

  DESCRIPTION OF SYMBOLS 10 Collective conducting wire, 12 Conductor strand, 14 Insulating film, 16 Adhesive, 18 External insulating film, 20 Bending part, 22 Inner peripheral side, 24 Outer peripheral side, 26 Side surface.

Claims (5)

In a set conductor wire in which a plurality of conductor wires having a rectangular cross section are arranged in parallel and integrated with each other,
Having a bend bent to form a coil;
The conductor strands arranged on the inner peripheral side of the bent portion are formed so that the width is smaller than the width of the other conductor strands.
A collective conductor characterized by that. The assembly conductor according to claim 1,
When the bent portion is formed by being bent only on one side, the inner conductor wire is formed so that the width thereof is smaller than the width of the conductor wire arranged on the outer periphery side,
A collective conductor characterized by that. The assembly conductor according to claim 1,
When the bent portion is formed by being bent to one side and the other side, the conductor wires arranged on both sides in the width direction are formed so that the width is smaller than the width of the other conductor wires. ,
A collective conductor characterized by that. A coil using the collective conducting wire according to any one of claims 1 to 3,
The assembly conductor is wound around the teeth of the stator.
A coil characterized by that. In the manufacturing method of the assembly conductor,
An arrangement step in which a plurality of conductor wires having rectangular cross-sections having different widths are arranged in parallel to each other;
A bending step of bending the conductor wires arranged together to form a bent portion;
Have
In the placement step, the conductor strands are placed so that the width of the conductor strand scheduled to be on the inner peripheral side of the bent portion is smaller than the width of the other conductor strands.
The manufacturing method of the assembly conducting wire characterized by the above-mentioned.

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