JP2014036478A - Winding wire of concentrated winding and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate a portion which becomes excessively higher for feeding out a lead wire.SOLUTION: A basic coil configured by winding over a rectangular wire (a) to mutually contact a long side is stacked over 2n stages ((n) is a natural number) in such a manner that short sides of the rectangular wire (a) are brought into contact. On the other hand, inner diameter side end portions of the rectangular wires (a) in the basic coil on each stage are welded mutually and outer diameter side end portions thereof are welded mutually by a step-up connecting part (c), other than feeding out the outer diameter side end portions of the rectangular wires (a) in the basic coils on the first stage and the 2n-th stage as lead wires a1, respectively. Therefore, by feeding the lead wire a1 of a concentrated winding coil from the outside, a portion that conventionally becomes excessively higher for feeding out the lead wire can be eliminated, such that a coil size is made compact.

Description

  The present invention relates to a winding by concentrated winding and a manufacturing method thereof. In particular, it is suitable as an armature winding or field winding of a wind power generator, and can also be applied as a field winding (complementary coil) of a DC machine.

In manufacturing the concentrated winding coil, a method of manufacturing by flatwise as shown in FIG. 11 or a method of manufacturing by edgewise coil as shown in FIG. 12 is used.
In the case of the flatwise winding shown in FIG. 11, the length of the flat wire a is indicated by the flat wire a as indicated by reference numerals 1 to 5 and 1 'to 4' which are the number of turns (the prime numbers have different directions even with the same number). Winding while shifting along the core so that the side becomes the inner surface with respect to the core (iron core: not shown) and the short sides of the flat wire a are in contact with each other.

Then, the flat wire a is moved to the outer diameter side as indicated by reference numerals 6 to 9, 5 'to 8', which are the number of turns, and the long side is connected to the long side of the flat wire a indicated by reference characters 2 to 5, 1 'to 4'. Are wound while being shifted in the opposite direction along the core so that the short sides of the flat wire a are in contact with each other.
Further, the flat wire a is moved to the outer diameter side as indicated by reference numerals 10 to 12, 9 'to 12', which are the number of turns, and the long side is extended to the long side of the flat wire a indicated by reference numerals 6 to 9, 5 'to 8'. Are wound while being shifted in the opposite direction along the core so that the short sides of the flat wire a are in contact with each other.
A flat wire a indicated by reference numeral 1 is drawn from the inner peripheral side as a lead wire a1, and a flat wire a shown by reference numeral 12 'is drawn from the outer diameter side as a lead wire a1.

  In the edgewise coil shown in FIG. 12, the short side of the flat wire b is the inner diameter surface with respect to the core (iron core: not shown), as indicated by reference numerals 1 to 12 and 1 'to 12' which are the number of turns of the flat wire b. At the same time, winding is performed while shifting along the iron core so that the long sides of the flat wire b are in contact with each other. Further, both end portions of the flat wire b are drawn out as lead wires b1.

Japanese Utility Model Publication No. 53-123154 JP 2010-29063 A

In the concentrated winding coil of FIG. 11, since the flat wire a indicated by reference numeral 1 that is the winding start of the coil is on the inside, it is necessary to dodge the winding start portion by the height of the electric wire in order to bring out the lead wire. It gets bigger.
In the edgewise coil of FIG. 12, the copper bar (flat wire b) is bent edgewise, the copper bar is welded, and the manufacturing man-hours are greatly generated.

  Patent Document 1 discloses a technique in which staggered winding portions are distributed in the coil extending direction in order to provide a lead wire. In FIG. 42 of Patent Document 2, the structure of the distributed winding stator is disclosed. It is disclosed that in the case of a rectangular wire or the like, it is difficult to arrange in a certain direction such as a thickness direction or a width direction, and the space factor is reduced.

  The winding by concentrated winding according to claim 1 of the present invention that solves the above problem is a 2n stage winding of a basic coil formed by winding rectangular wires so that their long sides are in contact with each other, so that the short sides of the rectangular wires are in contact with each other. (N is a natural number) While stacking, the outer ends of the rectangular wires in the first and second n-th basic coils are drawn out as lead wires, respectively. The inner diameter side end portions of the flat wire are welded to each other, and the outer diameter side end portions are welded to each other at a step-up connection portion.

  A winding by concentrated winding according to claim 2 of the present invention for solving the above-mentioned problems is characterized in that in the winding by concentrated winding according to claim 1, the step-up connecting portion is located at a coil end.

  The winding by the concentrated winding which concerns on Claim 3 of this invention which solves the said subject WHEREIN: The winding by the concentrated winding of Claim 1 or 2 WHEREIN: The said step-up connection part welds the side surface of the said rectangular wire. It is characterized by becoming.

  A winding by concentrated winding according to a fourth aspect of the present invention that solves the above problem is the winding by concentrated winding according to the first, second, or third aspect, wherein the step-up connecting portion is between the rectangular wire. It is characterized in that it is welded with stepped connection parts in between.

  A winding by concentrated winding according to claim 5 of the present invention for solving the above-mentioned problems is characterized in that in the winding by concentrated winding according to claim 4, the connecting parts have chamfered corners.

  The concentrated winding winding according to claim 6 of the present invention that solves the above-described problem is the concentrated winding winding according to claim 4 or 5, wherein the rectangular wire comprises a plurality of small angle wires. In the ascending connection portion, one of the small-angle lines is formed as a stepped portion protruding from the other, and the connecting component is formed with a stepped portion in surface contact with the stepped portion, and these stepped portions are overlapped with each other. It is also characterized by welding together.

  The winding by concentrated winding which concerns on Claim 7 of this invention which solves the said subject WHEREIN: The winding by concentrated winding of Claim 6 WHEREIN: In the said step-up connection part, the step part in the said rectangular wire, and the said connection component Each of the step portions is provided with positioning holes for positioning.

  The method of manufacturing a winding by concentrated winding according to claim 8 of the present invention that solves the above-described problem includes a step of creating a basic coil by winding a rectangular wire so that long sides thereof are in contact with each other, and Steps of stacking 2n steps (n is a natural number) so that the short sides of the flat wires are in contact with each other, and pulling out the outer diameter side ends of the flat wires in the first and second n-th basic coils as lead wires, respectively. Except for welding the inner diameter side ends of the rectangular wire in the basic coil of each step and welding the outer diameter side ends to each other at a stepped up connection portion.

According to the first aspect of the present invention, since the lead wire of the concentrated winding coil is pulled out from the outer diameter side, it is possible to eliminate the portion that has been excessively high in order to provide the lead wire, and the coil size. Becomes compact.
According to the second aspect of the present invention, since the stepped-up connection portion is located not at the side portion but at the coil end, the adhesion between the iron core and the coil is improved. Therefore, cooling capacity and insulation performance are improved.

According to the invention which concerns on Claim 3, a flat wire can be reliably connected in a step-up connection part.
According to the invention which concerns on Claim 4, the connection in the step-up connection part which is a very difficult operation | work can be performed easily by using a step-shaped connection component, and working efficiency improves.

According to the invention which concerns on Claim 5, the reliability of coil insulation or work efficiency improves by chamfering a connection component.
According to the invention which concerns on Claim 6, when a flat wire consists of several small angle wires, there exists an advantage by which a welding operation becomes easy by superimposing a step part mutually.

According to the seventh aspect of the present invention, since the positioning hole is provided, there is an advantage that the positioning with the connecting component is facilitated even when the flat wire is composed of a plurality of small-angle wires.
According to the eighth aspect of the present invention, since the lead wire of the concentrated winding coil is pulled out from the outer diameter side, it is possible to eliminate the portion that has been excessively high in order to provide the lead wire, so that the coil size is reduced. However, it is possible to manufacture a compact winding.

FIG. 1A is a plan view of a winding according to the first embodiment of the present invention, and FIG. 1B is a cross-sectional view taken along line AA ′ in FIG. FIG. 2A is a plan view of a winding according to a second embodiment of the present invention, and FIG. 2B is a cross-sectional view taken along the line BB ′ in FIG. It is a side view of a step-up connection part. It is a side view of step-like connection components. It is explanatory drawing of the chamfered step-like connection component. It is an arrow line view which shows the step-up connection part in the case of having two which corresponds to the EE arrow line view in FIG. It is an arrow line view which shows the step-up connection part in the case of having two which corresponds to the EE arrow line view in FIG. It is a perspective view of the step-up connection part provided with two positioning holes. It is a perspective view of the step-up connection part provided with two positioning holes. 10A shows the first stage basic coil, FIG. 10B shows the second stage basic coil, FIG. 10C shows the third stage basic coil, and FIG. 10D shows the fourth stage. It is a top view of the basic coil of a step. FIG. 11A is a plan view of a conventional flatwise winding, and FIG. 11B is a cross-sectional view taken along the line CC ′ in FIG. FIG. 12A is a plan view of a conventional edgewise winding, and FIG. 12B is a cross-sectional view along the line DD ′ in FIG. FIG. 13A is a plan view of a staircase-like connecting component and an iron core according to a seventh embodiment of the present invention, and FIG. 13B is a plan view of a staircase-shaped connecting component according to a seventh embodiment of the present invention. FIG. 13 (c) is a side view of the step-like connecting component according to the seventh embodiment of the present invention.

   Hereinafter, the present invention will be described in detail with reference to embodiments shown in the drawings.

FIG. 1 shows an armature winding or field winding of a wind power generator by concentrated winding according to the first embodiment of the present invention.
The present embodiment relates to a basic embodiment of the present invention, in which two lead wires a1 are both drawn from the outer diameter side.

That is, as shown in FIG. 1, the long sides are in contact with each other, as indicated by the reference numerals 1 to 3 and 1 ′ to 3 ′ which are the number of turns of the flat wire a (the prime numbers are attached in different directions even with the same number). The first stage basic coil is created by winding.
Next, as shown by reference numerals 4 to 6 and 4 'to 6' as the number of turns, the rectangular wire a is wound so that the long sides are in contact with each other to create a second-stage basic coil.

Further, as shown by the reference numerals 7-9 and 7'-9 'which are the number of turns, the rectangular wire a is wound so that the long sides are in contact with each other, thereby creating a third-stage basic coil.
Further, as shown by reference numerals 10 to 12 and 10 'to 12' which are the number of turns, the rectangular wire a is wound so that the long sides are in contact with each other to form a fourth-stage basic coil.

The number of turns and the number of stages used here are for convenience and do not indicate the order. In the drawing, four basic coils are used, but 2n (n is a natural number), that is, even basic coils can be used.
The basic coils of the first, second, third, and fourth stages created in this way are stacked so that the short sides of the rectangular wire a are in contact with each other. A core (iron core) is located at the center of these basic coils, but is omitted in the figure.

Then, as shown in FIG. 1, the outer diameter side end portion of the flat wire a having the number of turns 1 in the first-stage basic coil is drawn out as the lead wire a1, and the number of turns 12 'in the fourth-stage basic coil is The outer diameter side end of the flat wire a is drawn out as a lead wire a1.
On the other hand, except for the outer diameter side end of the flat wire a having the number of turns 1 and the outer diameter side end of the flat wire a having the number of turns of 12 ', that is, excluding the lead wire a1, the rectangular wires in the basic coils of each stage. The inner diameter side end portions of a are welded to each other, and the outer diameter side end portions are welded to each other via a step-up connection portion c.

That is, the inner diameter side end portion of the winding number 3 ′ in the first stage basic coil shown in FIG. 10A and the inner diameter side end portion of the winding number 4 ′ in the second stage basic coil shown in FIG. Are welded at the rising connection portion c.
Similarly, the outer diameter side end portion of the winding number 6 in the second stage basic coil shown in FIG. 10B and the outer diameter side end portion of the winding number 7 in the third stage basic coil shown in FIG. 10C. Are welded at the rising connection portion c.

Further, the inner diameter side end portion of the winding number 9 'in the third stage basic coil shown in FIG. 10 (c) and the inner diameter side end portion of the turn number 10' in the fourth stage basic coil shown in FIG. 10 (d). Are welded at the rising connection portion c.
Here, the step-up connection part c means a part connected across each basic coil.

In this way, each basic coil can be used as a single coil by being connected at the step-up connection c.
In this embodiment, as the step-up connection portion c, the side surfaces (short sides) of the flat wire a are welded to each other as shown in FIG.
In the present embodiment, since the lead wire a1 is on the outside of the coil, it is not necessary to dodge the electric wire and the height of the coil can be reduced as compared with the prior art.

FIG. 2 shows an armature winding or field winding of a wind power generator by concentrated winding according to a second embodiment of the present invention.
The present embodiment differs from the first embodiment in that the position of the ascending connection portion c is different.
That is, in the first embodiment, as shown in FIG. 1, the step-up connection portion c is located on the coil side (long side portion of the iron core), so as shown in FIG. 10, There is a possibility that a gap e is formed in the interstage portion, the adhesion to the iron core is deteriorated, and heat transfer to the iron core is hindered.

Therefore, in the present embodiment, as shown in FIG. 2, the step-up connection portion c is moved to the coil end portion (short side portion of the iron core) that is not in close contact with the iron core to suppress the formation of the gap e and the coil and the iron core are I tried to adhere as much as possible.
In the first embodiment, as shown in FIG. 10, the size of the gap e is about (1/2) of the long side of the iron core, whereas in this embodiment, as shown in FIG. The size of the gap e is about (1/2) of the short side of the iron core.

FIG. 2 is a schematic diagram in which the ratio of the long side to the short side of the iron core is relatively small, but as shown in Example 7 described later, the ratio of the short side to the long side of the iron core is actually quite small. Therefore, there is an effect of sufficiently reducing the gap e.
Other configurations are the same as those in the first embodiment, and the description thereof is omitted.

FIG. 4 shows an armature winding or field winding of a wind power generator using concentrated winding according to a third embodiment of the present invention.
In this example, the flat wire a was welded as the step-up connection portion c with a stepped connection component f interposed therebetween.

When the step connection portion c is moved to the coil end as in the second embodiment, since the flat wire a is narrow and the coil is curved in an arc shape, the welding operation at the step connection portion c is performed. Is very difficult and requires technology.
Therefore, the step-like connection part f as shown in FIG. 4 is used as the step-up connection part c. If it does in this way, the welding operation | work of the connection component f and the flat wire | line a can be performed not in a coil end part but in a coil linear part, and workability | operativity improves (refer FIG. 11). Other configurations are the same as those of the above-described embodiment, and the description is omitted.

FIG. 5 shows an armature winding or field winding of a wind power generator by concentrated winding according to a fourth embodiment of the present invention.
This embodiment is an improvement of the step-like connecting component f in the third embodiment.
That is, the staircase-like connecting component f used in the third embodiment is very difficult to wind the insulating tape at the corners, and the efficiency of the insulating work has deteriorated.

  Therefore, in this embodiment, as shown in FIG. 5, the corner portion of the step-like connecting component g is chamfered, that is, formed into an arc. As described above, since the insulating tape is easily wound, the efficiency of the insulating work is improved. Other configurations are the same as those of the above-described embodiment, and the description thereof is omitted.

FIG. 6 shows an armature winding or field winding of a wind power generator by concentrated winding according to a fifth embodiment of the present invention. 6 corresponds to the view taken along the line EE in FIG.
The present embodiment is applied to the case where there are two rectangular wires a, that is, when two small-angle wires h are used as the rectangular wires.
That is, when there are two rectangular wires a, as shown in FIG. 6, as shown in FIG. 6, a stepped portion h <b> 1 in which one small angle line h protrudes forward from the other small angle line h. Formed.

On the other hand, the step-shaped connecting component i has a width (size) corresponding to two small-angle lines h, and is in surface contact with the stepped portion h1 of one small-angle line h, that is, an opposite step-shape. The uneven part i1 was formed so as to be. And these uneven parts i1 and h1 were overlapped and welded.
If it does in this way, since many welding surfaces can be taken, workability | operativity will improve and the reliability of a welding part will improve. In this embodiment, the present invention is applied to the two small angle lines h, but the present invention can be similarly applied even when there are three or more lines.

FIG. 7 shows an armature winding or field winding of a wind power generator by concentrated winding according to a sixth embodiment of the present invention.
The present embodiment relates to the improvement of the fifth embodiment.
That is, as the two small-angle lines h, one or two positioning holes j are provided in the stepped portion h1 where one small-angle line h protrudes from the other small-angle line h.

Correspondingly, one or two positioning holes j are formed in the stepped portion i1 formed so as to be in surface contact with the stepped portion h1 of one small-angle line h as the stepped connection component i. Was provided.
FIG. 7 corresponds to the view taken along the line EE in FIG. 5, and the positioning hole j appears to be one, but as shown in FIG. 8, two positioning holes j are provided. Also good.
FIG. 9 is a modification of FIG. 8 in which two positioning holes j are provided.

That is, as shown in FIG. 9, as the two small-angle lines h, each small-angle line h is a stepped portion h1 that is cut out by a half width, and the stepped connection part i is also a stepped portion that is cut out by a half-width. i1 is provided with two positioning holes j in the uneven portions i1 and h1.
As described above, by providing one or two positioning holes j, it is easy to align the two small-angle lines h and the step-like connecting component i.

FIG. 11 shows an armature winding or field winding of a wind power generator by concentrated winding according to a seventh embodiment of the present invention.
This example is an example closer to the actual dimensions as shown in FIG.
That is, as shown in FIG. 11A, the ratio of the coil side (long side) on both the left and right sides in the figure is considerably large with respect to the upper and lower coil ends (short sides) in the iron core k. When the step-shaped connection component m is arranged at the end, the step-shaped connection component m is bent around the end n. Therefore, it turns out that the space | gap of the iron core k and a coil becomes quite small.

In this embodiment, since the stepped connection component m is bent around the end n, the welding operation of the connection component m and the flat wire is performed not at the coil end portion but at the coil linear portion. Workability is improved. In the drawing, the flat wire welded to the connection component m is omitted.
The step-like connecting component m has a corner chamfered (shown by hatching in FIG. 11 (b)) m1, and the insulating tape is easy to roll.

  In particular, the present invention can be widely used as an armature winding or field winding of a wind power generator, and can also be used as a field winding (complementary coil) of a DC machine. .

1 to 12, 1 ′ to 12 ′ Number of turns a, b Flat wire a1, b1 Lead wire c Step-up connection part e Gap f, g, i Stepped connection parts h Small angle line j Positioning hole

Claims (8)

While a basic coil formed by winding flat wires so that their long sides are in contact with each other is stacked in 2n stages (n is a natural number) so that the short sides of the flat wires are in contact,
Except that the outer diameter side ends of the rectangular wires in the first and second nth basic coils are drawn out as lead wires, respectively.
A winding by concentrated winding, wherein the inner diameter side ends of the rectangular wire in the basic coil of each stage are welded to each other and the outer diameter side ends thereof are welded to each other at a step-up connection portion. The winding by concentrated winding according to claim 1, wherein the step-up connection is located at a coil end. The winding by concentrated winding according to claim 1, wherein the step-up connection portion is formed by welding the side surface of the rectangular wire. The winding by concentrated winding according to claim 1, 2 or 3, wherein the step-up connection part is welded with a step-like connection part sandwiched between it and the flat wire. The winding by concentrated winding according to claim 4, wherein the connection part has chamfered corners. In the case where the rectangular wire is composed of a plurality of small-angle lines, in the step-up connection portion, one of the small-angle lines is a stepped portion protruding from the other, and the connecting component is in surface contact with the stepped portion. The winding by concentrated winding according to claim 4 or 5, wherein stepped portions are formed, and the stepped portions are overlapped and welded to each other. The winding by concentrated winding according to claim 6, wherein in the stepped-up connection portion, a positioning hole for positioning is provided in each of the stepped portion in the rectangular wire and the stepped portion in the connecting part. line. Winding a flat wire so that the long sides touch each other to create a basic coil;
Stacking the basic coil in 2n stages (n is a natural number) so that the short side of the rectangular wire is in contact;
Except for drawing out the outer diameter side ends of the rectangular wires in the first and second n-th basic coils as lead wires, the inner diameter side ends of the rectangular wires in the basic coils in each stage are mutually connected. And a step of welding the end portions on the outer diameter side with each other at the stepped-up connection portion.

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