JP2019161771A - Coil manufacturing method and electric device using the same - Google Patents

Abstract

To solve the problem in which, when manufacturing a coil that constitutes a winding structure with a merit of concentrated winding and distributed winding, since, in the prior art, a coil shape is formed using a mold after creating a winding, every time the coil shape changes, a mold has to be manufactured, which results in cost increase, and it was necessary to reinforce insulation of a conductor.SOLUTION: The coil manufacturing method includes: a step of bending in a direction of winding around a conductor (main bending step); and a step of forming a crank shape in a coil end arrangement portion (crank bending process). While sequentially performing the bending step in the direction of winding around the conductor and alternately creating the arrangement portion in the slot and the coil end arrangement portion, the conductor is wound in a circumferential shape. While sequentially performing steps of forming a crank shape on the coil end arrangement portion, by providing a gap of a thickness width of the conductor between adjacent conductors, it is possible to omit insulation enhancement of the conductor while suppressing the cost.SELECTED DRAWING: Figure 11

Description

The present invention relates to a winding structure used for a winding of an electric device such as a rotating device such as an electric motor and a generator, or a transformer, and an electric device using the same.

In a rotating device such as an electric motor or a generator, a winding is wound around a rotor or a stator, and in a linear motor, a winding is wound around a stator or a mover. In electrical devices such as transformers, windings are used as primary and secondary coils or tertiary coils.

As a winding method for such an electric device, there are a concentrated winding method in which the wire is wound around one iron core and a distributed winding method in which the wire is wound around a plurality of iron cores. In the case of concentrated winding, the coil end height can be reduced because the winding does not intersect with the coil ends of the other phases. However, there are a problem that the cogging torque is large and a disadvantage that the output per volume is smaller than that of the distributed winding. On the other hand, the distributed winding has the advantage that the cogging torque is small and the output per volume is larger than the concentrated winding. There is a demerit that the height of the coil end becomes higher. In order to solve the disadvantages of such distributed winding, various methods have been proposed in which the height of the coil end is suppressed.

For example, a winding structure combining concentrated winding and distributed winding has been proposed. This winding structure is formed by winding a conductor as a winding in a circumferential shape, and includes an in-slot arrangement portion arranged inside the slot of the stator core and a coil end arrangement portion arranged outside the slot. The coil end arrangement portion has a crank-shaped lane change portion. Although the single piece constituting this winding structure has a concentrated winding structure, the winding structure in which the single pieces are combined has a distributed winding structure, and each winding has the merits of concentrated winding and distributed winding. It has a structure.

As for the winding structure constituting the winding structure having the merits of the concentrated winding and the distributed winding, prior art literatures are clearly disclosed regarding a radial gap type motor mainly used for industrial applications. Patent Document 1 describes the above-described coil manufacturing method. Specifically, a step of forming a pair of coil end arrangement portions into a convex shape with an elliptical winding laminated with a gap of a conductor width between adjacent conductors while winding in a circumferential shape, and coil end arrangement A step of forming a crank shape on the part, a step of forming the position of the arrangement portion in the slot in accordance with the slot position of the radial gap type motor, and a step of forming the coil end arrangement portion in an arc shape. Manufacturing a coil is described. Patent Document 2 describes a motor that uses the coil shape described in Patent Document 1 in a radial gap type motor.

Japanese Patent No. 5613345 Japanese Patent No. 5560176

In Patent Documents 1 and 2 described above, the motor is limited to a radial gap type motor. However, as an application of the motor, the axial gap type motor can increase the torque. In addition, since the axial gap type motor is generally more efficient when it is flat with the shaft length shorter than the outer diameter, the axial gap type motor is used for applications such as large torque and flatness.

Regarding the coil of the axial gap type motor, the conductors of the pair of in-slot placement portions are not parallel, but the coil end placement portion is formed into a convex shape in a winding wound in a circumferential manner as in Patent Document 1. Therefore, it has a complicated structure, and the coil cannot be easily manufactured.

The present invention has been made in view of the problems of the prior art, and its purpose is to reduce a conductor processing time by a concentrated winding coil and a winding structure that realizes a cogging torque reduction by a distributed winding structure to an axial gap type. To provide to the motor.

A coil according to the present invention is formed by laminating conductors while being wound in a circumferential shape, and an in-slot arrangement portion arranged inside a slot of a stator core or a rotor core, and a coil end arrangement portion arranged outside the slot. In a method for manufacturing a coil, the method includes a step of bending the conductor in a direction to circulate (main bending step) and a step of forming the coil end arrangement portion into a crank shape (crank bending step), and the direction of wrapping the conductor While sequentially performing the bending process to the coil end arrangement portion, the winding in the slot shape and the coil end arrangement portion are alternately created, and the coil end arrangement portion is formed into a crank shape between the adjacent conductors. Is provided with a gap having a width that allows one conductor to pass through.

Further, the coil is constructed by combining a plurality of the created coils, and the method of constructing the coil is a coil of another phase between the spiral conductors of the coil from the direction perpendicular to the winding direction of the coil. It is characterized in that an axial gap type motor is formed by inserting a plurality of helical conductors and combining them multiple times.

  The coil manufacturing method and electrical equipment using the coil manufacturing method according to the present invention can reduce the size of the coil end with less cogging torque, which is the merit of concentrated winding and distributed winding.

It is an external appearance perspective view of a coil. It is the front view which looked at the coil in the lamination direction. It is the side view which looked at the coil from the coil end side. It is an external appearance perspective view of the coil | winding before the main bending process in coil shaping | molding. It is an external appearance perspective view of the coil | winding after the main bending process in coil shaping | molding. It is an external appearance perspective view of the coil | winding before the crank bending process in coil shaping | molding. It is an external appearance perspective view of the coil | winding after the crank bending process in coil shaping | molding. It is the figure which showed a mode that a coil was combined. It is a stator winding figure of an axial gap type motor. It is an external appearance perspective view of the stator core of an axial gap type motor. It is an external appearance perspective view of the stator which combined the stator core and stator winding | coil of an axial gap type motor.

  Here, the structure of the coil finally manufactured and the manufacturing method of the coil will be described, and then the coil assembly method and the motor incorporating the assembled coil will be described.

[Coil structure]
First, the structure of the coil 1 finally manufactured will be described. 1 is an external perspective view of the coil 1, FIG. 2 is a front view of the coil 1, and FIG. 3 is a side view of the coil 1 as viewed from the inner diameter side coil end arrangement portion. The coil 1 is composed of a flat conductor 10. Here, the flat conductor 10 is formed by forming a highly conductive metal such as copper or aluminum as a wire having a rectangular cross section, and the periphery thereof is covered with an insulating coating material such as enamel. Then, the coil 1 is manufactured by performing edgewise bending or flatwise bending on the flat conductor 10. Here, the “edgewise bending process” is a process in which the rectangular conductor 10 is bent in the long side direction with one surface on the short side in the rectangular cross section of the rectangular conductor 10 as the inner diameter surface and the other surface as the outer diameter surface. That is. The “flatwise bending process” is a process in which one side on the long side of the rectangular cross section of the flat conductor 10 is an inner diameter surface and the other surface is an outer diameter surface, and the flat conductor 10 is bent in the short side direction. That is.

  As shown in FIGS. 1 to 3, the coil 1 is formed by laminating a flat conductor 10 while winding it around. In the present embodiment, the direction in which the rectangular conductor 10 circulates is referred to as the circulation direction of the coil 1, and the direction in which the coil 1 is extended spirally is described as the axial direction. The coil 1 is formed in a spiral shape so that the long side surfaces face each other, and the rectangular conductors 10 are arranged with an interval h in the axial direction. The interval h is set to a size that allows insertion of the flat conductor 10 of another coil, and is slightly larger than the thickness (width in the short side direction) of the flat conductor 10.

  The coil 1 has an in-slot placement portion 11 and a coil end placement portion 12 formed therein. The in-slot arrangement portion 11 is a portion arranged between the teeth 31 (see FIG. 10) (referred to as a slot) when the coil 1 is arranged in the stator core 3 (see FIG. 10). In this in-slot arrangement portion 11, as shown in FIGS. 1 and 2, the flat conductor 10 is formed in a linear shape.

  The coil end arrangement | positioning part 12 is a part arrange | positioned outside a slot, when arrange | positioning the coil 1 in the stator core 3 (refer FIG. 10). This coil end arrangement | positioning part 12 is provided with the lane change part 13, as shown in FIGS. By providing the lane change portion 13 having such a shape, the coil end of the stator 4 can be reduced in size.

  Although the connecting wire is not described in the coil 1 of FIGS. 1 to 3, the connecting wire may be formed at the same time.

[Coil manufacturing method]
In the method of manufacturing the coil 1, the main bending process, which is edgewise bending or flatwise bending, is repeated in the circumferential direction of the coil 1, and the crank bending is sequentially performed at the coil end arrangement portion. This is repeated according to the number of turns necessary for the coil 1 to manufacture the coil 1.

The main bending process is sequentially performed along the circumferential direction in coil manufacturing, and the bending process of the main bending process scheduled portion 15 of the rectangular conductor 10 is performed before the main bending process at a certain time (see FIG. 4). As shown in FIG. 5, the main bending portion 16 is bent in the circumferential direction.

In addition, when the flat conductor 10 is twisted in a direction other than the winding direction, the fit into the slot is deteriorated. Therefore, when the main bending process is performed, it is desirable to perform the bending process while restraining the flat conductor 10.

The crank bending process is a process that is sequentially performed in the coil end placement portion while the main bending process is sequentially performed along the circumferential direction. In a state before the crank bending process at a certain point (see FIG. 6), the crank bending process of the crank bending process scheduled part 17 of the flat conductor 10 is performed, and the crank bending process part 18 is crank bent as shown in FIG. . Due to the crank bending process, the interval h between the flat conductors 10 adjacent to each other in the axial direction of the flat conductor 10 is slightly wider than the thickness of the flat conductor 10 of another coil.

〔motor〕
When the coil 1 is used for the motor, a plurality of coils 1 are used in combination as shown in FIG. Specifically, since there is an interval h slightly wider than the thickness of the rectangular conductor 10 between the rectangular conductors 10 adjacent in the axial direction, the rectangular conductor 10 of another coil 1 is connected to the interval h in FIG. Insert it in the direction of. When this is repeated and a plurality of layers are stacked, the rectangular conductor 10 of the slot arrangement portion 11 of another coil 1 is accommodated in the gap between the flat conductors 10 of the in-slot arrangement portion 11 of the coil 1.

  When the coil 1 is assembled in this way, the stator winding 2 is formed. FIG. 9 shows a stator winding of an axial gap type motor. The stator winding 2 can be formed by preparing 36 coils 1.

  When combined with the stator core 3, the stator winding 2 becomes a stator 4 of an axial gap type motor.

  It should be noted that the above-described embodiment is merely an example and does not limit the present invention in any way, and various improvements and modifications can be made without departing from the scope of the invention.

1 Coil 2 Stator winding (combined coil)
3 Stator Core 4 Stator 10 Flat Rectangular Conductor 11 In-Slot Arrangement Part 12 Coil End Arrangement Part 13 Lane Change Part 14 Coil End Arrangement Part (Excluding Lane Change Part)
15 Main bending process part 16 Main bending process part 17 Crank bending process part 18 Crank bending process part 31 Stator core (teeth)
32 Teeth 鍔 33 Stator yoke h Clearance

Claims (2)

  In a manufacturing method of a coil comprising: a conductor being laminated while being circumferentially wound; and an in-slot arrangement portion arranged inside a slot of a stator core or a rotor core, and a coil end arrangement portion arranged outside the slot, It has a process of bending in the direction of winding the conductor (main bending process) and a process of forming a crank shape in the coil end arrangement portion (crank bending process), and sequentially bending the conductor in the direction of winding While performing the process of forming the in-slot arrangement portion and the coil end arrangement portion alternately while winding them around, and sequentially forming the coil end arrangement portion into a crank shape, one conductor passes between the adjacent conductors. A coil comprising a gap having a width. The coil is configured by combining a plurality of coils according to claim 1, wherein the coil is arranged in a phase different from the direction perpendicular to the winding direction of the coil between coils of the coil. An axial gap type motor characterized in that a plurality of helical conductors are inserted and combined.