JP2020010042A - Coil manufacturing device, coil manufacturing method and coil - Google Patents

Abstract

To provide a coil manufacturing device and a coil manufacturing method capable of improving space factor and heat dissipation, and enabling mass production of coils while circumventing characteristic deterioration due to cutting and joining, and to provide the coil.SOLUTION: A coil manufacturing device 20 includes a first holding part 11 and a second holding part 12 forming a spiral structure by joining multiple strip conductors C1, C2 forming a spiral shape when being continued, capable of clamping the conductor and other conductor, respectively, and placed oppositely and movably in a first direction. The first and second holding parts are constituted, respectively, of first support materials 111, 112 and second support materials 121, 122 capable of moving in a second direction. One support material end face constituted of one end face of the first support material and one end face of the second support material is located in a space in the spiral structure.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a coil manufacturing apparatus using a conductor, a coil manufacturing method, and a coil.

  Examples of a coil device in which a coil is arranged around a core (stator core) of a stator core (stator) include electric devices such as a motor, a generator, and a transformer. It is important to improve the space factor of the coil in the core in order to reduce the size and size.

  Conventionally, as a coil capable of improving the space factor in a core, a coil using a rectangular conductor (hereinafter, referred to as a rectangular coil) has been known. A flat coil is also called a flat-wound (square-wound) coil, a square (square) coil, an edgewise coil, or the like, and is used for winding a round conductive wire having a substantially circular cross-section orthogonal to the longitudinal direction. Means a coil formed by winding a rectangular conductor having a rectangular cross section orthogonal to the longitudinal direction.

  As a method for manufacturing a rectangular coil, a method of winding a long rectangular conductor (square conductor) into a substantially rectangular shape is known (for example, see Patent Document 1). Also known is a method in which a rectangular conductor (a flat conductive material) having a length of one turn of a coil is laminated, the lower end upper surface and the upper start lower surface are overlapped and repeated by a joining means to form a spiral structure. (For example, see Patent Document 2).

  As a method for connecting conductors, a cold pressure welding method is known.

Japanese Patent No. 3881520 JP 2005-130676 A

  However, in the method of winding a long rectangular conductor into a substantially rectangular shape as in the technique described in Patent Document 1, the corners (both on the outer peripheral side and the inner peripheral side) are curved and rounded. It is inevitable to become. Since the core is generally in the shape of a prism having a substantially right-angled corner, if a rounded coil is provided around the core, a space is created between the core and the coil. In this space, heat is accumulated during operation of the coil device, so that the heat dissipation of the coil device is deteriorated, and there is a problem that the efficiency of the coil device cannot be increased due to an increase in coil resistance. Also, there is a limit to the improvement in the space factor of the coil at the corners.

  In addition, since the rectangular conductor used for the coil has its outer periphery coated with an insulating resin in advance, when the coil is wound, the coating becomes thinner due to the curvature at the outer corner, and the withstand voltage of the coil device decreases. there were.

  On the other hand, in the case of a method of laminating and joining rectangular conductors for one turn of a coil as in the technique described in Patent Document 2, it is also possible that the corners are not curved, and the above-described heat dissipation and space factor Problem can be avoided. However, although the connection is made by the joining means, it is inevitable that the characteristics of the joint between the lower end upper surface and the upper start lower surface are deteriorated as compared with the uncut portion, and the operation is stabilized. Problems remain in terms of aspects.

  In addition, as one method of connecting conductors, a method of cold-welding round wire conductors is known, but flat-shaped conductors are satisfactorily cold-welded by improving the stability of the connection part. It was difficult.

  Further, in a coil manufacturing apparatus and a coil manufacturing method for manufacturing a coil by successively pressing a plurality of conductors into pressure, studies from the viewpoint of improving mass productivity have not been sufficient.

  An object of the present invention is to provide a coil manufacturing apparatus, a coil manufacturing method, and a coil capable of improving a space factor and improving heat dissipation, and capable of mass-producing a coil that avoids characteristic deterioration due to cutting and joining. Aim.

  The present invention has solved the above problems by the following means.

  The present invention is a coil manufacturing apparatus for forming a spiral structure by joining a plurality of strip-shaped conductors which can be formed into a spiral shape when being continuous, wherein the conductor and the other conductor can be sandwiched by each other, and A first holding unit and a second holding unit are provided facing each other and are movable in a first direction, and the first holding unit and the second holding unit are respectively arranged along a second direction. A first holding body and a second holding body that can be moved in the same direction, and one holding body including one end face of the first holding body and one end face of the second holding body. The end face is located in a space inside the spiral structure, according to the coil manufacturing apparatus.

  In addition, the present invention provides a plurality of strip-shaped conductors that can be formed into a spiral structure when they are continuous, and connects one of the conductors or a connected body of the plurality of conductors (hereinafter, referred to as “the preceding conductor”) to another of the conductors ( Hereinafter, referred to as “the latter conductor”), wherein the leading conductor is deformed in the spiral traveling direction of the spiral structure in at least a part of the region other than the vicinity of the end. Then, the end is connected to the end of the subsequent conductor, which relates to a method for manufacturing a coil.

  Further, the present invention is a coil formed of a spiral structure in which strip-shaped conductors are continuously formed in a spiral shape, and in a part of a first circumference of a spiral of the spiral structure, along a spiral traveling direction. The coil is characterized in that it is deformed so that a step is formed, and is deformed so that a step is formed along the spiral traveling direction in a part of a second circumference that is continuous with the first circumference. It is related.

  Further, the present invention is a method for manufacturing a coil in which a plurality of strip-shaped flat conductors that can be a spiral structure when continuous are prepared, and the spiral structure is formed by joining end faces of the plurality of the flat conductors, A pressure contact step of abutting and pressing one end surface of the first flat conductor in the band longitudinal direction and one end surface of the second flat conductor in the band longitudinal direction, and intersects in the band longitudinal direction and the band short direction by pressing. And a removing step of removing burrs protruding in a direction to be performed.

  According to the present invention, it is possible to provide a coil manufacturing apparatus, a coil manufacturing method, and a coil, which are capable of improving the space factor and improving heat dissipation, and capable of mass-producing a coil while avoiding characteristic deterioration due to cutting and joining. be able to.

FIG. 1A is an external view (a front view) schematically illustrating a configuration of a cold pressure welding apparatus according to the present embodiment. (B) It is a top view of a flat conductor. FIG. 2C is a sectional view taken along line AA of FIG. FIG. 2 is an external view (front view) schematically illustrating a holding unit of the cold pressing apparatus according to the embodiment. FIG. 2 is an external view (front view) schematically illustrating a holding unit of the cold pressing apparatus according to the embodiment. It is a side view which showed typically the holding part of the cold pressure welding apparatus which concerns on this embodiment. It is a top view which shows the rectangular conductor which concerns on this embodiment. It is a schematic diagram showing a situation of cold pressure welding of the rectangular conductor according to the present embodiment. It is a figure which shows the coil manufacturing apparatus which concerns on this embodiment, (a) It is a side view of a holding part, (b) It is a front view of a coil, (c) It is a front view of a holding part. It is a side view of a holding part of a coil manufacturing device concerning this embodiment. It is a schematic diagram explaining the coil manufacturing method concerning this embodiment. It is a schematic diagram explaining the coil manufacturing method concerning this embodiment. It is a modification of the coil piece according to the present embodiment. It is a figure explaining the modification of the coil manufacturing device and coil manufacturing method concerning this embodiment. It is a figure explaining the coil concerning this embodiment, (a) It is a front view, (b) It is a sectional view, (c) It is a side view. It is a figure showing the experimental result about the calorific value of the coil concerning this embodiment, and the coil of the conventional example. It is a figure explaining the attachment method to the status core of the coil concerning this embodiment, (a) It is a side view, (b) It is sectional drawing of the figure (a), (c) The figure (a) FIG. It is a side view showing the spiral structure of the coil concerning this embodiment. It is a figure which shows the spiral structure of the coil which concerns on this embodiment, (a) is an external perspective view, (b) is a side view, (c) is an external perspective view, and (d) is a side view.

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

<Cold pressure welding device>
FIG. 1 is a diagram illustrating a cold pressure welding apparatus 10 according to the present embodiment. FIG. 1A is an external view (a front view) schematically illustrating a configuration of the cold pressure welding apparatus 10. FIG. 1B is a top view of the flat conductor C, and FIG. 1C is a cross-sectional view taken along line AA of FIG. 1B.

  As shown in FIG. 1A, a cold-welding device 10 is a device for cold-welding two flat conductors C (C1, C2), and includes a first holding portion 11 and a second holding portion 12. Have. In the following description, the flat conductor C refers to a band-shaped (tape-shaped) conductor formed in a plane with respect to a round conductor, as shown in FIGS. That is, the flat conductor is a band-shaped member having two opposing wide surfaces WS and two opposing narrow surfaces WT and being long in a predetermined direction, as shown in FIGS. A cross section orthogonal to the band longitudinal direction BL (cross section taken along the line AA in FIG. 2B) is a rectangular or rounded rectangular conductor as shown in FIG. In the following description, as an example of the flat conductor, a flat rectangular conductor having a rectangular cross section orthogonal to the longitudinal direction of the band (the upper figures in FIGS. 3B and 3C) will be described. In addition, the flat conductor C in the present invention may be a band-shaped conductor formed in a plane with respect to a round wire conductor, and has a substantially square cross section along the line AA in FIG. It may be.

  The first holding portion 11 is movable along a first direction (longitudinal direction of the rectangular conductor; X direction in FIG. 2A), and is moved by a first upper holding member 111 and a first lower holding member 112. Be composed. The first upper holder 111 and the first lower holder 112 are arranged to face each other so as to have an opposing surface OS1 along a first direction (hereinafter, referred to as an X direction). In the present embodiment, for convenience of explanation, the upper holding body in the drawing is referred to as a first upper holding body 111 and the lower holding body in the drawing is referred to as a first lower holding body 112. It is not limited to top and bottom. That is, FIG. 1A may be a top view of the cold pressure welding apparatus 10, in which case, the first upper holding body 111 is, for example, a back side holding body, and the first lower holding body 112 is, for example, a near side. Side holding body. Further, the first upper holder 111 may be, for example, a left holder, and the first lower holder 112 may be, for example, a right holder.

  The first upper holder 111 and the first lower holder 112 are movable along the X direction, and the opposing surface OS1 along the X direction is oriented in the second direction (the thickness direction of the rectangular conductor; It is possible to move so as to abut or separate from each other along the direction (Y direction in FIG. The Y direction is a direction different from the X direction, for example, a direction orthogonal to the X direction.

  The second holding unit 12 is disposed to face the first holding unit 11 so as to have an opposing surface OS2 along a second direction (hereinafter, referred to as a Y direction) between the first holding unit 11 and the first holding unit 11. It has the same configuration as the first holding unit 11. Therefore, although detailed description is omitted, the second holding unit 12 is movable along the X direction, and includes a second upper holding body 121 and a second lower holding body 122. The description “up and down” of the second upper holder 121 and the second lower holder 122 is the same as that of the first holder 11.

  The second upper holder 121 and the second lower holder 122 are movable along the X direction, and are movable such that the opposing surfaces OS1 are in contact with or separated from each other along the Y direction.

  Further, the first holding portion 11 and the second holding portion 12 are urged by an urging member (for example, a coil spring) 15 in a direction away from each other along the X direction. Although not shown, the first upper holding body 111 and the first lower holding body 112 are urged by an urging member (for example, a coil spring) in a direction away from each other along the Y direction, and The upper holding body 121 and the second lower holding body 122 are urged by an urging member (for example, a coil spring) in a direction away from each other along the Y direction.

  The movement of the first rectangular conductor C1 and the second rectangular conductor C2 in the Y direction is restricted by movement restriction means (not shown). Further, the first rectangular conductor C1 and the second rectangular conductor C2 can move in the direction approaching along the X direction, but are restricted from moving in the direction away from each other.

    A pressing portion 18 is provided outside the first holding portion 11 and the second holding portion 12 in the Y direction. The pressing portion 18 presses the first upper holding body 111 and the first lower holding body 112 so as to make contact with each other, and also presses the second upper holding body 121 and the second lower holding body 122 so as to make contact with each other. Press them.

  FIG. 2 and FIG. 3 are front views in which the first holding unit 11 and the second holding unit 12 are extracted, and are diagrams showing a state of their movement.

  FIG. 2 mainly shows Y of the first holding unit 11 (the first upper holding body 111 and the first lower holding body 112) and the second holding unit 12 (the second upper holding body 121 and the second lower holding body 122). It is a figure explaining movement along a direction.

  In the state shown in FIG. 5A, the opposing surfaces OS1 of the first upper holder 111 and the first lower holder 112 (also the second upper holder 121 and the second lower holder 122) are the most in the Y direction. It is a position to be separated. This position is hereinafter referred to as a Y direction separation position. In this state, the position where the opposing surfaces OS2 of the first holding unit 11 and the second holding unit 12 are most separated from each other in the X direction is hereinafter referred to as an X direction separation position.

  FIG. 2B shows a state where the state has been moved from the state shown in FIG. 1A to a position where the opposing surfaces OS1 of the first upper holder 111 and the first lower holder 112 abut. In this state, the first holding unit 11 sandwiches the first rectangular conductor (the wide surface WS) between the first upper holding body 111 and the first lower holding body 112, and the second holding unit 12 holds the second upper holding body 121. The second rectangular conductor (the wide surface WS) is sandwiched between the second lower holding body 122 and the second lower holding body 122.

  The first holding unit 11 sandwiches the first rectangular conductor C1 from the facing surface OS2 along the Y direction by protruding in the direction of the second holding unit 12. Similarly, the second holding unit 12 sandwiches the second rectangular conductor C2 from the facing surface OS2 along the Y direction so as to protrude toward the first holding unit 11. The protrusion amount A1 of the first rectangular conductor C1 from the first holding portion 11 and the protrusion amount A2 of the second rectangular conductor C2 from the second holding portion 12 will be described later.

  The position where the opposing surfaces OS1 of the first upper holder 111 and the first lower holder 112 (the second upper holder 121 and the second lower holder 122) abuts in this manner is referred to as a holding position in the following description. That is, the first upper holding body 111 and the first lower holding body 112 (the second upper holding body 121 and the second lower holding body 122) can move between the sandwiching position and the Y-direction separation position.

  Further, as shown in FIG. 3C, a release position (in the Y direction) of the holding is included between the holding position and the Y direction separation position. The release position in the Y direction (hereinafter, the release position in the Y direction) is smaller than the separation position in the Y direction, and is smaller than the first upper holder 111 and the first lower holder 112 (the second upper holder 121 and the second lower holder). Body 122).

  The position where the opposing surfaces OS1 of the first upper holder 111 and the first lower holder 112 (the second upper holder 121 and the second lower holder 122) abuts from the Y direction release position in FIG. To the state shown in FIG.

  Note that, in FIG. 2, the positions along the X direction of the first holding unit 11 and the second holding unit 12 are all maintained in the X direction separation positions.

FIG. 3 is a diagram illustrating movement of the first holding unit 11 and the second holding unit 12 mainly along the X direction.
FIG. 3A shows a position where the first holding unit 11 and the second holding unit 12 have moved along the X direction from the state of FIG. Hereinafter, this position is referred to as a proximity position. That is, the first holding unit 11 and the second holding unit 12 are movable between the X-direction separated position shown in FIG. 2 and the close position shown in FIG. Even at the close position, the first holding unit 11 and the second holding unit 12 do not abut.

  The first holding unit 11 projects and clamps the first rectangular conductor C1 by the projection amount A, and the second holding unit 12 projects and clamps the second rectangular conductor C2 by the projection amount A2 ( 2 (b), when the first holding unit 11 and the second holding unit 12 are in the close position, the first holding unit 11 and the second holding unit 12 do not abut, but the first rectangular conductor C1 and the second The rectangular conductors C2 are in contact (joining), and are pressed against each other. That is, the protrusion amount A1 of the first rectangular conductor C1 from the first holding portion 11 and the protrusion amount A2 of the second rectangular conductor C2 from the second holding portion 12 are respectively equal to the first holding portion 11 and the second holding portion 12. When they are in the proximity position, the amount is slightly longer than the length of contact (the amount that can be pressed after contact).

  Further, as shown in FIG. 2B, a release position (in the X direction) of the pressing is included between the approach position and the X-direction separation position (FIG. 2A). The release position in the X direction (hereinafter, the X direction release position) is a position where the first holding unit 11 and the second holding unit 12 are separated by a distance smaller than the X direction separation position. When the first holding unit 11 and the second holding unit 12 are at the X-direction release position, the first upper holder 111 and the first lower holder 112 are also separated and moved to the Y-direction release position, and 121 and the second lower holding body 122 are also separated from each other and move to the Y-direction release position.

  In addition, it is possible to make a transition from the X-direction release position in FIG.

  FIG. 4 is a side view of the first holding unit 11 as viewed from the second holding unit 12 side toward the opposing surface OS2 of the first holding unit 11 (a view in the direction of the arrow V in FIG. 1). 2A shows a state in which the first upper holding body 111 and the first lower holding body 112 are separated from each other in the Y direction (the state shown in FIG. 2A), and FIG. 2 (FIG. 2 (b)).

  The first upper holding body 111 has a rectangular conductor holding groove 111A at a position close to one end face (right end face in the figure) 111S in the third direction (horizontal direction of the rectangular conductor; Z direction in the figure). The first lower holding body 112 is provided with a rectangular conductor holding groove 112A at a position close to one end face (right end face in the figure) 112S in a third direction (hereinafter, referred to as a Z direction). The third direction (Z direction) is a direction different from the X direction and the Y direction, respectively, and is a direction orthogonal to both directions.

  One end face 111S of the first upper holding body 111 and one end face 112S of the first lower holding body 112 are located on the same plane, and one end face in the third direction (Z direction) is shown in FIG. Reference numeral 1 denotes a front face of the first upper holding body 111 and the first lower holding body 112, and an end face close to an operator.

  The rectangular conductor holding grooves 111A and 112A are located inside the first upper holding body 111 and the first lower holding body 112 at a distance d1 in the third direction (Z direction) from the end surfaces 111S and 112S of the first upper holding body 111 and the first upper holding body. This is a rectangular groove provided on the facing surface OS1 of the body 111 and the first lower holding body 112.

  Further, as will be described later in detail, the rectangular conductor holding grooves 111A and 112A need to securely hold (sandwich) the rectangular conductor. Therefore, the shape is in conformity with the outer shape of the rectangular conductor, and the depth d3 of the groove is less than half the thickness d2 of the rectangular conductor (the first rectangular conductor C1 in this case) to be sandwiched. . Specifically, the depth of the rectangular conductor holding grooves 111A and 112A is about 5/100 mm smaller than 1/2 of the thickness d2 of the rectangular conductor.

  As shown in FIG. 2B, when the opposing surfaces OS1 of the first upper holder 111 and the first lower holder 112 are in contact with each other (when they are at the sandwiching position (FIG. 2B)), the rectangular conductor is used. The holding grooves 111 </ b> A and 112 </ b> A become one rectangular pillar-shaped hole penetrating the first holding part 11 in the X direction, and the rectangular conductor (the first rectangular conductor C <b> 1) is compressed in the hole in the thickness d <b> 2 direction. In a state (a state in which the plate thickness is reduced), it is in close contact with the rectangular conductor holding grooves 111A and 112A, and is held between the first holding portions 11 (the first upper holding body 111 and the first lower holding body 112).

  Although illustration is omitted here, the same applies to the second holding unit 12, and the second upper holding body 121 has one end face (the front face close to the worker) in the third direction (Z direction). A rectangular conductor holding groove 121A is provided at a position close to the rectangular shape, and a rectangular conductor holding groove 122A is provided at the second lower holding body 122 at a position close to one end face in the third direction. The configuration of the rectangular conductor holding grooves 121A and 122A is the same as the configuration of the rectangular conductor holding grooves 111A and 112A of the first holding unit 11.

  The first holding unit 11 and the second holding unit 12 are in one of a sandwiching state, a pressed state, a pressed state, a retracted state, and a transition state between two of these states.

  Referring again to FIGS. 2 and 3, in the sandwiching state, the first upper holder 111 and the first lower holder 112 of the first holding unit 11 are separated from each other in the Y direction along the Y direction (see FIG. a)) to the holding position (FIG. 2B), the first upper holding body 111 and the first lower holding body 112 hold the first rectangular conductor C1 and the second holding section 12 The upper holding body 121 and the second lower holding body 122 are moved from the Y direction separation position (FIG. 2A) to the sandwiching position (FIG. 2B) along the Y direction, and the second upper holding body 121 and the second lower holding body 122 are moved. The second rectangular conductor C2 is held by the second lower holding body 122.

  As described above, the first holding unit 11 sandwiches the first rectangular conductor C1 so as to project from the facing surface OS2 along the Y direction in the direction of the second holding unit 12 by the projection amount A1, and the second holding unit 12 The second rectangular conductor C2 protrudes from the opposing surface OS2 along the Y direction in the direction of the first holding portion 11 by a protruding amount A2 and is sandwiched.

  At this time, the pressing portion 18 (see FIG. 1A) presses the first upper holding body 111 and the first lower holding body 112 so that they contact each other, and presses the second upper holding body 121 and the second lower holding body 112. These are pressed so that the body 122 abuts. Thereby, the first rectangular conductor C1 and the second rectangular conductor C2 are in close contact with the rectangular conductor holding grooves 111A, 112A, 121A, 122A in a state where the first rectangular conductor C1 and the second rectangular conductor C2 are compressed in the thickness direction (the thickness is reduced). It is sandwiched between the holding unit 11 and the second holding unit 12 (see FIG. 4).

  In the sandwiching state, the first upper holder 111 and the first lower holder 112 of the first holder 11 at the Y-direction release position (FIG. 2C) are moved to the clamping position (FIG. 2B). The first rectangular conductor C1 is sandwiched between the first upper holding body 111 and the first lower holding body 112, and the second upper part of the second holding part 12 at the Y direction release position (FIG. 2C) is moved. The case where the holding body 121 and the second lower holding body 122 are moved to the holding position (FIG. 2B) to cause the second upper holding body 121 and the second lower holding body 122 to hold the second rectangular conductor C2. is there.

  Also at this time, the pressing portion 18 presses the first upper holder 111 and the first lower holder 112 so that they contact each other, so that the second upper holder 121 and the second lower holder 122 contact each other. These are pressed. Thereby, the rectangular conductor holding grooves 111A, 112A, 121A, 122A are formed in the holes in a state where the first rectangular conductor C1 and the second rectangular conductor C2 are compressed in the thickness direction (the thickness is reduced). The first holding unit 11 and the second holding unit 12 adhere to each other (FIG. 4).

  In the pressure contact state, the first holding portion 11 and the second holding portion 12 in the sandwiching state are moved from the X-direction separated position (FIG. 2A) along the X direction against the urging force of the urging member 15. It moves to the close position (FIG. 3A). At this time, the first rectangular conductor C1 protrudes from the first holding part 11, and the second rectangular conductor C2 protrudes from the second holding part 12. These protruding amounts A1 and A2 are respectively larger than the length of contact between the end faces facing each other in the band longitudinal direction when the first holding unit 11 and the second holding unit 12 are in the close position (FIG. 3A). It is slightly longer. That is, before moving to the close position (immediately before), the opposing end faces of the first rectangular conductor C1 and the second rectangular conductor C2 first contact (contact). Thereafter, when the first holding unit 11 and the second holding unit 12 move to the close position (FIG. 3A), the end faces of the first rectangular conductor C1 and the second rectangular conductor C2 that contact each other abut each other. They are pressed together and joined. More specifically, by pressing the end faces of the first rectangular conductor C1 and the second rectangular conductor C2, a stable oxide film formed on the end faces is removed, and these are plastically deformed to form an active state. Expose the surface. By bringing the surfaces in the active state closer to 10 angstroms or less, atomic bonding between the metals is caused, and cold welding is performed. That is, by the cold pressure welding, the first rectangular conductor C1 and the second rectangular conductor C2 are compressed (shortened) in the longitudinal direction of the band after the pressure welding compared to before the pressure welding. The amount of shortening is the same for the first rectangular conductor C1 and the second rectangular conductor C2. In other words, when the length of the first rectangular conductor C1 before the pressure contact is L01 and the length of the second rectangular conductor C2 before the pressure contact is L02, the first rectangular conductor C1 has the length L01 ′ and the second length by the pressure contact. The length of the rectangular conductor C2 is shortened to L02 ', and the shortened amounts S are all the same (S = L01-L01' = L02-L02 ').

  After moving to the proximity position, the first holding unit 11 and the second holding unit 12 do not come closer to each other, so that the first and second flat conductors C1 and C2 are no longer closer to each other. The pressing stops.

  In the pressure contact state, the first upper holding member 111 and the first lower holding member 112 at the Y direction release position (FIG. 2C) or the Y direction release position and the X direction release position (FIG. 3B). Then, the second upper holding body 121 and the second lower holding body 122 are moved to the sandwiching position (FIG. 2B), and the first holding portion 11 and the second holding portion 12 resist the urging force of the urging member 15. Then, the end face of the first rectangular conductor C1 and the end face of the second rectangular conductor C2 are pressed against each other to perform cold pressure welding (FIG. 3A).

  In the pressure-releasing state, the first holding unit 11 and the second holding unit 12 in the pressing state are moved in a direction in which they are separated from each other along the X direction, and the first holding unit 11 and the second holding unit 12 are moved to the X-direction release position. Go to Further, the first upper holder 111 and the first lower holder 112 are moved in a direction separating from each other along the Y direction, and the first upper holder 111 and the first lower holder 112 are moved to the first Y direction release position. I do. Further, the second upper holding body 121 and the second lower holding body 122 are moved in the direction separating from each other along the Y direction, and the second upper holding body 121 and the second lower holding body 122 are moved to the second Y direction release position. (FIG. 3B).

  In the pressure contact state, the first holding unit 11 and the second holding unit 12 finally reach the close position, and the further pressing of the first rectangular conductor C1 and the second rectangular conductor C2 stops, so that the pressing is repeated. After the pressure contact state, the state transits to the clamping state via the pressure contact release state, and the first rectangular conductor C1 and the second rectangular conductor C2 are reclamped by the first holding unit 11 and the second holding unit 12.

  Here, when the state changes from the pressed state to the released state (when the pressed state is released), the first upper holder 111 and the first lower holder 112 (the second upper holder 121 and the second upper The same applies to the lower holding body 122). However, as shown in FIG. 4, there is almost no clearance between the rectangular conductor holding grooves 111A, 112A, 121A, 122A and the first rectangular conductor C1 and the second rectangular conductor C2. Part of the metal that has flowed due to the deformation (the expanded joint surface) enters the slight clearance (for example, a corner of the groove) of the rectangular conductor holding grooves 111A, 112A, 121A, and 122A to increase the adhesion, and the urging member 15 May not be able to separate the first upper holder 111 and the first lower holder 112 (also the second upper holder 121 and the second lower holder 122).

  Therefore, in the present embodiment, in the pressure release state (FIG. 3B), in addition to the urging force of the urging member 15, the first holding unit (the first upper holding body 111 and the first lower holding body 112) is moved. Along the X direction, it is moved in a direction away from the second holding unit 12 to return to the first X direction release position, and the second holding unit (the second upper holding body 121 and the second lower holding body 122) is moved in the X direction. Along the direction away from the first holding unit 11 to return to the second X direction release position.

  In addition, even when the first holding unit 11 and the second holding unit 12 are forcibly moved in the direction in which the first holding unit 11 and the second holding unit 12 are separated from each other in addition to the urging member 15, the movement of the first flat conductor C1 and the first rectangular conductor C1 are not illustrated. The movement of the second rectangular conductor C2 in the direction away from each other along the X direction is restricted.

  In the retracted state, the first holding unit 11 and the second holding unit 12 in the pressed state, the pressed state, or the sandwiched state are moved to the X direction separated position along the X direction. (1) The lower holding body 112 is moved along the Y direction to the Y direction separation position, and the second upper holding body 121 and the second lower holding body 122 are moved along the Y direction to the Y direction separation position. It moves (FIG. 2A).

  The cold pressure welding apparatus 10 can perform cold pressure welding with a single press of the rectangular conductors, but it is desirable to repeat pressing a plurality of times for one joint to stabilize the joint surface. As an example, the amount of one press (the amount of compression) of the cold press apparatus 10 is about 0.5 mm for both the first rectangular conductor C1 and the second rectangular conductor C2. Then, the pressing (cold pressure welding) is repeated three to four times for one joint part, and when it is compressed by about 1 mm or more (preferably 1.5 mm or more, specifically about 2 mm), stable joining is achieved. The surface is obtained.

  For this reason, the cold pressure welding device 10 of the present embodiment repeatedly presses the first rectangular conductor C1 and the second rectangular conductor C2 by repeating the sandwiching state, the pressure contact state, and the pressure release state.

  As shown in FIG. 3A, when the first holding portion 11 and the second holding portion 12 are brought into the close position after the sandwiching state and moved to the close position, the end faces of the first rectangular conductor C1 and the second rectangular conductor C2 are connected to each other. Through contact (contact), the end faces are pressed and cold pressed. Since the first holding unit 11 and the second holding unit 12 at the close position do not come closer to each other, the state temporarily shifts to the pressure release state (FIG. 3B) and the first holding unit 11 and the second holding unit 12 The holding unit 12 is moved to the Y direction release position to release the holding of the rectangular conductor, and the first holding unit 11 and the second holding unit are moved to the X direction release position. Then, the first rectangular conductor C1 is held by the first holding portion 11 so that the predetermined protrusion amount A1 protrudes by transition to the sandwiching state, and the second rectangular holding portion 12 is held by the second holding portion 12 such that the protrusion amount A2 protrudes. By holding the single rectangular conductor C2 and transitioning to the pressure contact state again, a plurality of pressings can be repeated for one joint.

  That is, the X direction release position is a position where the first holding unit 11 can protrude and hold the first rectangular conductor C1 by the projection amount A1, and the second holding unit 12 protrudes the second rectangular conductor C2. This is a position at which it can be protruded and pinched by the amount A2.

  Note that the X-direction release position does not have to be a position where each of the rectangular conductors protrudes by the protruding amounts A1 and A2 when the state transits to the sandwiching state thereafter (as it is). In this case, in the sandwiching state, the first holding unit 11 and the second holding unit 12 may be moved to positions where the rectangular conductors project by the protrusion amounts A1 and A2, and then may be held.

  Further, in the above-described embodiment, the configuration in which the first holding unit 11 and the second holding unit 12 stop at the X direction release position and the Y direction release position in the pressure release state has been described as an example. The Y direction release position may pass, but may not stop at the position. That is, the first upper holder 111 and the first lower holder 112 (the same applies to the second upper holder 121 and the second lower holder 122) do not move between the holding position, the Y direction release position, and the Y direction separation position. The first holding unit 11 and the second holding unit 12 may move without stopping between the approach position, the X direction release position, and the X direction separation position. .

  Conventionally, cold pressure welding has been used to join round wires. However, according to the cold pressure welding device 10 of the present embodiment described above, good and stable cold pressure welding of rectangular conductors can be performed. Can be.

  Further, by using the coil pieces as the rectangular conductors (the first rectangular conductor C1 and the second rectangular conductor C2), the cold pressure welding device 10 can be used as the coil manufacturing device 20. This will be described below.

<Coil manufacturing equipment>
<Coil manufacturing equipment / rectangular conductor (coil piece)>
First, the rectangular conductor C used in the coil manufacturing device 20 of the present embodiment will be described with reference to FIG. FIG. 5 is a top view of the wide surface WS of the rectangular conductor C. The rectangular conductor C is a plurality of strip-shaped rectangular conductors having a linear shape ((a) in the figure) or having at least one bent portion ((b) to (e) in the figure) and having a spiral shape when they are continuous. These are hereinafter referred to as coil pieces. It is assumed that the coil pieces having bent portions are bent in the same direction in the longitudinal direction of the band so as to have a spiral shape when they are made continuous. In the case of a coil piece having a bent portion, the bent portion preferably has at least one non-curved (for example, substantially right-angled) shape.

  In the following description, a coil structure (a spiral structure to be completed) is a spiral structure in which a plurality of coil pieces (rectangular conductors) are continuously (connected). Shall be In other words, in the following description, a coil piece (a rectangular conductor) includes a minimum unit coil piece having a straight portion or a bent portion in the same direction in the band longitudinal direction of 1 to 4 and a plurality of the minimum unit coil pieces. And a coil piece in which one or more spiral structures of a coil (spiral structure to be completed) are formed. For the sake of convenience, when these distinctions are necessary, the minimum unit coil piece is called a unit coil piece, and a plurality of unit coil pieces are connected and completed as a coil (spiral structure to be completed). The coil piece before the schedule is called a bonded coil piece, and the spiral structure to be completed (completed state) is called a coil. In addition, it is assumed that each of the plurality of coil pieces has substantially the same shape and area of a cross section perpendicular to the belt longitudinal direction.

  As shown in the figure, the unit coil piece C0 is formed into a shape having a straight or substantially right-angled non-curved bent portion (corner portion) by punching a copper plate (for example, 1 mm thick) as an example. You. That is, the unit coil piece C0 has a straight shape (I-shape) without a bent portion (FIG. 9A) and an L-shape having one bent portion (FIG. 9B) when viewed from above the wide surface WS. U-shaped (U-shaped) having two bent portions (FIG. (C)), C-shaped having three bent portions (FIG. (D)), having four bent portions and the same There is a C-shape (substantially O-shape (substantially R-shape)) that bends in the direction (FIG. 3E). In each case, it is assumed that the bent portion (corner) has a substantially right angle.

  The plurality of coil pieces (unit coil pieces and / or joined coil pieces) have a preparation length L0 that is the total distance in the band longitudinal direction, and the completed spiral structure (coil) in the spiral longitudinal direction is to be completed. It is set to be longer than the length by a margin. The margin is set to a shortened total distance that is shortened by pressing when all of the plurality of coil pieces are cold pressed. The prepared length L0, the completed length, the allowance, and the shortened total distance will be described in detail in the description of the coil manufacturing method described later.

<Coil manufacturing device / holding unit>
Since the coil manufacturing apparatus 20 of the present embodiment is an application example of the above-described cold pressure welding apparatus 10, the same components as those of the cold pressure welding apparatus 10 are denoted by the same reference numerals, and redundant description will be omitted. A preferred configuration used for the coil manufacturing apparatus 20 will be mainly described.

  Referring again to FIG. 1, the coil manufacturing apparatus 20 includes a first holding unit 11 and a second holding unit 12 that can sandwich a rectangular conductor and another rectangular conductor, and are disposed to face each other. A spiral structure is formed by joining a plurality of strip-shaped rectangular conductors (coil pieces) that can be formed into a spiral shape when they are continuous to form a coil. The preparatory length, which is the distance, is set to be longer than the completed length of the spiral structure to be completed in the spiral longitudinal direction by a margin, and the end faces of the plurality of rectangular conductors (coil pieces) are stripped. Pressing along the longitudinal direction, cold-welding while shortening the distance in the belt longitudinal direction, and setting the total shortened distance to shorten all of the multiple rectangular conductors (coil pieces) by cold-welding to a margin That form a spiral structure A.

  That is, in the coil manufacturing apparatus of the present embodiment, the length of the coil pieces (joined coil pieces) held by the first holding unit 11 or the second holding unit 12 increases as the number of times of joining (joining times) of the coil pieces increases. Therefore, the configurations of the first holding unit 11 and the second holding unit 12 are suitable for use in manufacturing coils.

  First, FIG. 6 is a schematic diagram of a coil piece being manufactured by the coil manufacturing apparatus 20. FIG. 3A is a schematic view (top view) of the prepared unit coil pieces, and FIGS. 3B to 3D are development views of the unit coil pieces and the joined coil pieces in the course of manufacture. FIG. 7E is a view in the direction of arrow V in FIG.

  Here, as an example, a plurality of (here, four) U-shaped (U-shaped) unit coil pieces C0 having two bent portions are prepared, and these are connected (connected) to form a two-turn spiral shape. The case where the coil (spiral structure) 50 made of is manufactured is shown as an example. The two-dot chain lines at both ends of the coil pieces in FIGS. 8B to 8D indicate the finished ends of the completed coil, and in this example, the finished ends do not change (the finished ends in the horizontal direction in the drawing). (The position of the end does not move.)

  First, in the first cold welding, one end faces (indicated by circles) of two unit coil pieces C01 and C02 are connected to each other to form a joint coil piece CC1 as shown in FIG. Then, in the next cold welding, one end face of the joined coil piece CC1 (one of the end faces of the unit coil pieces C01 and C02 not joined) and the unit coil piece C03 are cold-welded, and the joined coil piece CC2 is formed (FIG. 3 (c)), and in the next cold welding, one end face of the joined coil piece CC2 (one of the unjoined end faces of the unit coil pieces C01 and C03) and the unit coil piece C04 is cold-pressed to complete the coil 50 (FIG. 4D).

  That is, the first holding portion 11 or the second holding portion 12 holds the bent (here, U-shaped (U-shaped)) coil pieces and joins the coil pieces CC1, CC2,. Is present near the first holding unit 11 or the second holding unit 12, the first holding unit 11 and the second holding unit 12 need to be configured to avoid interference with these coil pieces.

  FIG. 7 is a diagram for explaining the configuration of the first holding unit 11. FIG. 7A illustrates one unit coil piece C <b> 0 as the first holding unit 11 (the first upper holding body 111 and the first lower holding body 11). FIG. 112 is a diagram showing a state of holding at (112), and a front view of a surface OS2 facing the second holding unit 12; FIG. 2B is a front view of the completed coil 50 as viewed from the axial center of the spiral structure, and the coil piece of FIG. 2A is a cross-sectional view taken along line BB of FIG. 2B. It corresponds to the figure. Here, the first holding unit 11 will be described, but the same applies to the second holding unit 12. FIG. 2C is a front view of the first holding unit 11 (a sectional view taken along line AA in FIG. 2A).

  As shown in FIGS. 3A and 3B, when the coil piece has two or more bent portions (for example, a U-shaped (U-shaped) coil piece), the first holding portion 11 is joined to the first holding portion 11. In the area other than the coil piece (see FIG. 7A), there is a possibility that the coil piece C0 ′ that is U-turned from the coil piece C0 held by the first holding portion 11 and extends toward the front side may interfere. In this embodiment, in order to avoid this, the dimensions of the first holding portion 11 and the coil piece (the coil 50 to be completed) satisfy the following relationship.

  That is, when connecting a U-shaped (U-shaped) coil piece, one end face 111S of one of the first holding parts 11, specifically, the first upper holding body 111, and the same face The end face of the first lower holding body 112, which is composed of one end face 112S of the first lower holding body 112, and which is perpendicular to the facing surface OS2, has an internal space of a helical structure (the space which is to be the internal space of the helical structure also). (Hereinafter, this end face is referred to as a spiral inner end face IS). The spiral inner end surface IS is, for example, the front surface of the first holding unit 11 close to the worker.

  Therefore, in order to avoid interference between the first holding portion 11 and the coil piece, the rectangular conductor holding grooves 111A and 112A of the first holding portion 11 need to be provided at appropriate positions. The distance d1 to the ends (upper ends in the figure) of the rectangular conductor holding grooves 111A and 112A is a spiral along the third direction (Z direction in the drawing: short side direction of the coil piece that performs cold pressure welding). It is assumed that the distance is smaller than the distance D1 of the internal space of the structure (coil 50).

  Further, the length d4 of the first holding unit 11 in the X direction (FIG. 10C) is smaller than the distance D2 of the internal space of the spiral structure (coil 50) along the X direction (FIG. 10B). Shall be.

  After the two coil pieces are cold-pressed, a burr 55 is generated at the connection portion by extrusion. Therefore, after the completion of the cold welding, the coil pieces (joint coil pieces) are taken out from the first holding section 11 and the second holding section 12 and deburred, and the coil pieces (joint coil pieces) and another (new) coil piece are joined together. Cold pressure welding is performed between the coil pieces.

  FIG. 8 is a view corresponding to FIG. 7A (as viewed from the same direction), and shows a state in which the joint coil pieces CC are formed. In the coil manufacturing apparatus 20 of the present embodiment, the joined coil pieces CC are formed on one side of the first holding unit 11 (the same applies to the second holding unit 12), here on the first lower holding body 112 side. On the other hand, since the rectangular conductor holding grooves 111A and 112A of the first holding portion 11 are straight grooves along the X direction, at the time of cold welding, only the straight part including one end face of the joint coil piece CC is provided. Are held by the first holding unit 11. Therefore, in order to avoid interference between the joining coil piece CC and the first holding portion 11 (the first lower holding body 112), the coil piece (here, the joining coil piece CC) is spirally wound except for the vicinity of the end face where it is cold pressed. Cold pressing is performed between the coil pieces held by the second holding portion 12 while elastically and / or plastically deformed so as to expand in the spiral traveling direction of the structure (the direction along the Y direction).

  The deformation amount D3 of the elastic deformation and / or plastic deformation of the coil piece (here, the bonded coil piece CC) in the spiral traveling direction is set to an amount that avoids interference between the first holding portion 11 and the coil piece. In other words, the length (thickness) d5 along the Y direction of the holding body (here, the first lower holding body 112) of the first holding unit 11 on which the bonded coil piece is formed is the coil piece (here, the bonding piece). It should be smaller than the deformation D3 allowed for the elastic deformation and / or plastic deformation of the coil piece CC) in the spiral traveling direction.

  As described above, the coil manufacturing apparatus 20 according to the present embodiment forms the spiral structure by connecting the coil pieces by cold welding while elastically deforming and / or plastically deforming the coil pieces in the spiral traveling direction (the direction along the Y direction). is there. In the meantime, during the manufacturing, the coil pieces are connected (added) in a state of spreading in the spiral traveling direction, but after the spiral structure in a completed state is formed, the spiral structure is integrally molded (for example, , Press, etc.) and perform elastic deformation and / or plastic deformation to compress the spiral in the traveling direction to form the coil 50 in which each circumference of the spiral is close.

  The coil manufacturing apparatus 20 according to the present embodiment uses a coil piece that is longer (or longer) by the amount of compression (shrinkage) by cold compression based on the completed length of the coil, and is compressed by cold compression (longer). While shrinking) is repeated, coil pieces are added to produce a coil having a desired length L.

  Therefore, at the time of cold pressure welding, cold pressure welding is performed while measuring the distance of the coil piece in the band longitudinal direction. The measurement of the distance in the band longitudinal direction is performed, for example, by providing a slip detection mechanism (not shown) in the first holding portion 11 and the second holding portion 12 (or in the vicinity thereof), so that the coil pieces held by the first holding portion 11 are provided. By detecting slippage when the (first coil piece) and the coil piece (second coil piece) held by the second holding unit 12 are pressed, the distance in the belt longitudinal direction can be measured. The measurement of the distance in the longitudinal direction of the band may be performed simultaneously (in real time) with the cold welding, or may be measured before or after (or before or after) the cold welding. As a result, it is possible to realize a highly accurate coil dimension after completion.

  In addition, as shown in FIG. 7B, the substantially right-angle bent portion of the coil piece is a corner of the coil 50. In other words, according to the coil manufacturing apparatus 20 of the present embodiment, the inner and outer corners are formed at substantially right angles by joining the coil pieces having a substantially right-angle bent portion by punching or the like. Can be manufactured. Conventionally, a coil made of a rectangular conductor was manufactured by winding a long rectangular conductor, but it is inevitable that at least the inner corner of the coil will have a curved shape in winding. There is a limit to the improvement of heat dissipation and heat dissipation.

  However, according to the coil manufacturing apparatus of the present embodiment, it is possible to join the shapes formed by the punching process, so that a right-angled (substantially right-angled) corner can be realized even on the inner circumferential side of the coil, and the space factor is improved. In addition, it is possible to manufacture a coil capable of improving heat dissipation by eliminating an extra space.

  In particular, the joining portion CP is provided in a straight line portion avoiding the bent portion (corner portion). That is, pressure welding is performed using the linear portion of the coil piece. As a result, it is possible to improve the shape accuracy of the bent portion, and for example, it is possible to maintain a corner portion formed at a right angle (substantially right angle) in a punching process.

<Coil manufacturing method>
Next, a method for manufacturing a coil according to the present embodiment will be described. The coil manufacturing method according to the present embodiment can be implemented, for example, in the above-described coil manufacturing apparatus 20.

  That is, the coil manufacturing method of the present embodiment prepares a plurality of strip-shaped rectangular conductors (coil pieces) which can be formed into a spiral structure when they are continuous, and prepares a total distance of the plurality of rectangular conductors (coil pieces) in the strip longitudinal direction. The length L0 is set to be longer by a margin M than the completed length L of the spiral structure (coil) to be completed in the spiral longitudinal direction, and the end faces of the plurality of rectangular conductors (coil pieces) are connected to each other. Pressing along the longitudinal direction of the band, cold-welding while shortening the distance in the longitudinal direction of the band, and shortening the entire length of the plurality of rectangular conductors (coil pieces) by cold-welding to a shortened total distance S to a margin M. By setting, a spiral structure (coil) is formed by joining a plurality of rectangular conductors (coil pieces).

  Specifically, referring to FIG. 9, four U-shaped (U-shaped) unit coil pieces C0 (C01 to C04) each having two bent portions are prepared, and these are connected (continuously). A case in which a coil (spiral structure) 50 having a spiral shape of two turns is manufactured will be described as an example. 6A is a top view of the coil pieces C01 to C04, and FIGS. 6B to 6D are development views of the connection coil pieces. The center of the axis of the spiral structure of the coil 50 (the center of the joint CP) is shown. The two-dot chain lines at both ends of the coil pieces in FIGS. 8B to 8D indicate the finished ends of the completed coil. In this example, the finished ends do not change (in the horizontal direction in the drawing). (The position of the finished end does not move.)

  Assuming that the lengths of the unit coil pieces C01 to C04 in the band longitudinal direction are L01 to L04, the preparation length L0 which is the total distance in the band longitudinal direction is L01 + L02 + L03 + L04. The prepared length L0 is set to be longer than the completed length L of the coil 50 in the spiral longitudinal direction by a margin M (L0 = L + M). When the unit coil piece C01 and the unit coil piece C02 are pressed along the band longitudinal direction and cold pressed, the unit coil piece C01 is compressed by the pressing to reduce the length L01 in the band longitudinal direction to L01 ′ (shortened ( The amount of compression is the length of the distance S1 from the center of the joint CP), and the length L02 of the unit coil piece C02 in the longitudinal direction of the band is compressed to L02 ′ (the amount of (shortening (compression) is the distance of the distance S2 from the center of the joint CP). (A length LC1) to form a joined coil piece CC1 (length LC1) ((b) in the figure), and an end face of the joined coil piece CC1 (an end face of the unit coil piece C01 or C02 that is not joined). When the unit coil piece C03 is cold-welded, the unit coil piece C03 is compressed to L03 'by these pressings (the amount of shortening (compression) is the length of the distance S3 from the center of the joint CP). , It is compressed to C1 '((the amount of shortening (compression) is the length of the distance S4 from the center of the joining portion CP)) to form the joining coil piece CC2 ((c) in the same figure). When the unit coil piece C04 is cold-welded to the end face of the unit coil piece C01, C03 where the unit coil pieces C01 and C03 are not bonded, the unit coil piece C04 is compressed to L04 'by these pressings (the amount of shortening (compression) is reduced at the joint part). The joint coil piece CC2 is compressed into LC2 '(the amount of shortening (compression) is the length of the distance S6 from the center of the joint CP), and the completed length in the spiral longitudinal direction (start point). A coil 50 (spiral structure) having a length L from ST to the end point SE is completed ((d) in the figure), and the coil pieces (unit coil pieces and / or joining coil pieces) are joined to complete the coil 50. Until the coil piece is short The sum of the amounts (shortened total distance S = S1 + S2 + S3 + S4 + S5 + S6) corresponds to the margin M.

  The method of manufacturing the coil according to the present embodiment will be described again in chronological order. First, based on the length L of the completed coil 50, the lengths L01 to L04 of the unit coil pieces are set so that the shortened total distance S = the allowance M, and the amount of compression S1 to cold compression welding S1 to L4. S6 is set.

  Then, using the coil pieces set in this way, the end faces of the unit coil pieces C01 and C02 are pressed against each other by the set compression amounts S1 and S2, and added by cold pressing to form the joined coil pieces CC1. I do. The compression amounts S1 and S2 at this time can be grasped by measuring the distance between the two coil pieces in the belt longitudinal direction by detecting slippage when the unit coil pieces C01 and C02 are pressed. The method of determining the amount of compression is the same in the following cold pressure welding.

  After cold-welding one joining region (for example, near the end face where the unit coil piece C01 and the unit coil piece C02 are joined), burrs are generated by pushing the joining part. I do.

  Next, the spiral movement direction of the spiral structure to be completed is left, except for the vicinity of the end face (the end face of the unit coil piece C01 or the unit coil piece C02 where the unit coil piece C01 or C02 is not joined) of the coil piece (bonded coil piece CC1). While being elastically and / or plastically deformed, cold pressure welding is performed with another coil piece (unit coil piece C03). At this time, the deformation amount of the elastic deformation and / or the plastic deformation of the joining coil piece CC1 in the spiral traveling direction is determined by the first holding portion 11 and the second holding portion 12 where the coil piece is held at the time of cold pressing, the joining coil piece. It is set to an amount that avoids interference with CC1. The deformation amount is the same in the following cold press welding.

  Hereinafter, coil pieces are similarly added. That is, the end face of the joined coil piece CC1 (the end face of the unit coil piece C01 or C02 not joined) and the unit coil piece C03 are pressed by the set compression amounts S3 and S4, and replenished by cold welding to join. The coil piece CC2 is formed. Thereafter, the joint area is deburred, and the joint coil piece CC2 is elastically and / or plastically deformed in the spiral traveling direction of the spiral structure to be completed while leaving the vicinity of the end face to be cold-welded. The end face of CC2 and the unit coil piece C04 are pressed by the set compression amounts S5 and S6 and added by cold pressing to obtain a completed spiral structure.

  FIG. 10 is a diagram illustrating an example of a completed spiral structure 50 ′ (the number of turns of the coil is different from that of the above-described embodiment). 10A is a front view as viewed from the direction of the spiral axis, FIG. 10B is an arrow view (side view) in the V direction before molding, and FIGS. 10C and 10D are after molding. FIG.

  The completed spiral structure 50 'is formed by press working or the like. That is, in order to avoid buffer between the first holding portion 11 and the second holding portion 12 at the time of cold pressing, elastic deformation and / or plastic deformation are performed in the spiral traveling direction of the spiral structure, so that the space between the spirals can be reduced. Since an unnecessary and non-uniform spread (space) is formed in the spiral structure, the spiral structure is elastically deformed and / or plastically deformed in the spiral traveling direction so as to compress the spiral space. It is brought close (close) (FIG. 3 (c)).

  Further, if necessary, according to the shape of the stator core, the inner side may be concave or convex in the axial center direction (radial direction of the stator core) of the spiral structure, that is, as shown in FIG. The peripheral end is formed into a curved shape that is not flush with the outer peripheral end.

  Thereafter, the formed spiral structure is immersed in a liquid insulating resin and integrally coated with the insulating resin. Note that the spiral structure after molding may be integrally coated with the insulating resin by spraying a liquid insulating resin. Conventionally, a long conductor corresponding to the completed length of the coil is covered with an insulating resin and then wound to form a spiral structure. However, in this case, the insulating resin is stretched in the vicinity of the outer periphery of the curved portion of the winding, so that the coating thickness is reduced, and this is a cause of the deterioration of the withstand voltage. In addition, for example, when coating with an insulating resin before the above-described molding, a similar problem occurs because the coating thickness of the insulating resin varies by pressing. In the present embodiment, since the spiral structure molded into a shape to be attached to the stator core is integrally covered with the insulating resin after the molding, the uniformity of the film thickness of the insulating resin can be improved. In addition, since the spiral structures are integrally coated with the insulating resin after the molding, the spiral structures can be bonded to each other with the insulating resin, and can be coated with a uniform film thickness.

<Modified example of coil piece>
FIG. 11 is a diagram illustrating a connection example when the shape of the coil pieces is different.

  FIG. 3A is a top view showing a connection example using L-shaped coil pieces. Here, a case where four L-shaped coil pieces C0 are used to form a connection coil piece for one round is shown. Is shown. Although illustration is omitted for convenience of explanation, in this case also, the prepared length L0, which is the total distance of each coil piece in the band longitudinal direction, is the completed length in the spiral longitudinal direction of the spiral structure (coil) to be completed. The length L is set to be longer than the length L by a margin M. The margin M is set to a shortened total distance S that is shortened by pressing when all of the plurality of coil pieces are cold pressed.

  It is not necessary that all the connection coil pieces for one round have the same shape (L-shape). That is, an L-shaped I-shaped (linear) or U-shaped (U-shaped) coil piece may be combined to form a connection coil piece for one round.

  FIG. 2B is a top view showing a connection example in which a C-shaped coil piece C0 and an I-shaped coil piece C1 are combined. Although illustration is omitted for convenience of explanation, in this case also, the prepared length L0, which is the total distance of each coil piece in the band longitudinal direction, is the completed length in the spiral longitudinal direction of the spiral structure (coil) to be completed. The length L is set to be longer than the length L by a margin M. The margin M is set to a shortened total distance S that is shortened by pressing when all of the plurality of coil pieces are cold pressed.

  Further, a connection coil piece for one round may be formed by combining a substantially C-shaped coil piece with three corners and an L-shaped coil piece. Further, the coil pieces constituting the first and second turns of the spiral structure may be different combinations.

  FIG. 4C shows a coil piece C0 having two U-shaped (U-shaped) corners and a coil piece (O-shaped (B-shaped) coil for one round of the spiral structure to be completed). It is a development view in the case of forming a joined coil piece by combining the C1 and C1). The two-dot chain lines at both ends of the coil piece in the drawing indicate the finished end of the completed coil. In this example, the finished end does not change (the position of the finished end does not move in the left-right direction in the drawing). ).

  The joined portion of the O-shaped coil piece C1 is cut. When one end of the U-shaped coil piece C0 and one end of the O-shaped coil piece C1 are cold-pressed, the U-shaped coil piece C0 has a compression amount S0, and the O-shaped coil piece C1 has a compression amount S1. It can be compressed and repeated to form a helical structure. In FIG. 9, (in the case of using a U-shaped coil piece C0 having the same length), as shown in the figure, the joining portion CP is located at substantially the same position along the axis center of the spiral structure in each circumference of the spiral structure. In the case of FIG. 11C, the joint CP is formed at a position shifted by a predetermined amount along the axis center (dashed line) of the spiral structure in each circumference of the spiral structure. You.

<Modified example of coil>
FIG. 12 is a diagram illustrating a modification of the coil manufacturing apparatus and the coil manufacturing method. 10A is a schematic view of the coil manufacturing apparatus 20 ′, and FIG. 10B is a side view of the coil 50 manufactured by the same, corresponding to FIG. 10C. c) is a perspective view of the coil 50.

  The coil manufacturing apparatus 20 'includes a plurality of holding units 22 each including the above-described first holding unit 11 and second holding unit 12, as shown in FIG. 9A, and the plurality of holding units 22 (22A to 22E) include: The width W of the rectangular conductor holding grooves 111A, 112A, 121A, 122A of the first holding portion 11 and the second holding portion 12 (width along the Z direction, width of the rectangular conductor in the short side direction BS) is different (sequentially). It may be larger (or smaller).

  As described above, by using the plurality of holding units 22 having different widths W of the rectangular conductor holding grooves 111A, 112A, 121A, 122A, it is possible to join rectangular conductors having different widths (widths WA to WE in the figure). That is, by sequentially moving between the plurality of holding units 22 and performing cold pressure contact with different holding units 22 for each circumference of the spiral structure, a spiral structure having a different length for each circumference of the coil is formed. it can. That is, the U-shaped (U-shaped) unit coil pieces having the same length in the longitudinal direction of the band are used to cold-weld and connect the coil pieces while sequentially moving between the plurality of holding units 22. Thus, the coil 50 having the truncated quadrangular pyramid outer shape (FIGS. (B) and (c)) can be formed.

  In addition, a plurality of holding units 22 having different depths d3 of the rectangular conductor holding grooves 111A, 112A, 121A, 122A may be used. In that case, the plate thickness of each periphery of the spiral structure constituting the coil 50 can be made different.

<Coil>
Next, the coil of the present embodiment will be described with reference to FIG. FIG. 13A is a front view of the spiral structure viewed from the axial center direction, and FIG. 13B is a cross-sectional view taken along line AA of FIG. FIG. 1C is a side view of FIG. 1A viewed from the V direction.

  The coil 50 of the present embodiment is formed of a spiral structure in which strip-shaped rectangular conductors (coil pieces) are continuously formed in a spiral shape. As shown in FIG. It has a non-curved corner (a substantially right-angle corner) 50C. Here, as an example, it is manufactured using the above-described coil manufacturing apparatus and coil manufacturing method.

  In a conventional coil formed by winding a long rectangular conductor longer than one round of the spiral structure of a completed coil, it is inevitable that the bent portion has a curved structure. Creates a large space. Since the blank portion has a higher heat retaining effect, there is a limit in improving the heat radiation of the coil. In addition, when a long rectangular conductor is wound after being covered with an insulating resin, there is a problem that the coating thickness of the insulating resin is thin at the bent portion, and the pressure resistance is deteriorated.

  On the other hand, since the coil 50 of the present embodiment can be formed by punching a shape corresponding to one round of the spiral structure of the coil, a coil having a desired shape can be formed in a front view. That is, the coil 50 having a shape that is extremely close to the shape of the stator core (at least the inner peripheral corner 50C is a right angle or a substantially right angle) is obtained. Thereby, unlike the coil of the winding type, the space between the coil and the stator core 60 (shown by a broken line in FIG. 7A) can be minimized. For example, the length of the space (the distance from the inner peripheral side of the coil 50 to the stator core 60) per side of the coil 50 can be reduced to 0.5 mm to 1.0 mm, thereby improving the heat radiation. In addition, since the insulating resin can be coated with a high degree of uniformity over the entire coil 50, deterioration of the withstand voltage due to variation in the thickness of the insulating resin can be suppressed.

  Further, in the coil 50 of the present embodiment, the width (width W1 of the coil piece in the width direction of the coil piece) orthogonal to the spiral traveling direction of the spiral structure is widened at the corners and becomes the width W2, thereby also reducing the coil resistance. can do.

  Furthermore, since the cold pressure welding is an atomic bond of a metal, the connection portion is securely joined to such an extent that it cannot be visually recognized. As a result, the stability of the connection portion can be greatly improved as compared with a configuration in which the coil for one turn (or less) is connected in a plane with an adhesive (fixing material, brazing, or the like).

  Also, as shown in FIG. 2B, the first circumference of the spiral of the spiral structure (for example, the first circumference by the joint coil piece CC1) is partially formed, and the other part of the rectangular conductor (coil piece) is formed. A first thin portion T1 having a thickness D8 smaller than the thickness D7 is provided. In addition, the second circumference (for example, the second circumference due to the joint coil piece CC2) that is continuous with the first circumference partially has a plate thickness D8 greater than the plate thickness D7 of the other rectangular conductor (coil piece). A thin second thin portion T2 is provided.

  As described above, the coil piece is sandwiched by the first holding unit 11 and the second holding unit 12 of the coil manufacturing apparatus 20 at the time of cold pressing, and at this time, the total depth of the rectangular conductor holding grooves 111A and 112A ( The same applies to the total depth of the rectangular conductor holding grooves 121A and 122A) is smaller than the thickness D7 of the coil piece. Then, the coil pieces are pressed by the pressing portion 18 and held between the first holding portion 11 and the second holding portion 12, so that the holding portions are formed by the rectangular conductor holding grooves 121A and 122A and the rectangular conductor holding grooves 111A and 112A. It is compressed in the plate thickness direction to a thickness (D8) approximately equal to the total depth. The portions sandwiched by the first holding portion 11 and the second holding portion 12 are a first thin portion T1 and a second thin portion T2. That is, the first thin portion T1 and the second thin portion T2 are formed corresponding to the joint portion CP of the cold pressure welding, for example, by connecting U-shaped (U-shaped) coil pieces. In the case of such a coil, the first thin portion T1 is provided at two locations on the first circumference, and the second thin portion T2 is also provided at two locations on the second circumference. When the lengths of the U-shaped unit coil pieces are all the same, the first thin portion T1 and the second thin portion T2 overlap each other in the axial center direction of the spiral structure, as indicated by the dashed square. Is provided.

  Further, as shown in FIG. 11, the first thin portion T1 and the second thin portion T2 formed corresponding to the joining portion CP of the cold pressure welding have U-shaped (U-shaped) and O-shaped coil pieces as shown in FIG. In the case of the O-shaped coil piece, the first and second circumferences are alternately shifted in correspondence with the joint CP. (Thin portions are formed only at one place in one round.)

  The coil 50 has a spiral structure in which the entire periphery is integrally covered with an insulating resin. Thereby, the adhesiveness of each circumference of the spiral structure can be increased. Further, a gap SP of the coil piece is formed between the first thin section T1 and the second thin section T2, and a part of the insulating resin is also embedded in the gap SP. That is, as described in the above-described manufacturing method, after the spiral structure is completed (the molding is performed as necessary), the spiral structure is immersed in the liquid insulating resin, so that the insulating resin enters the gap SP. Thereby, the adhesiveness of each circumference of the spiral structure can be further enhanced.

  Further, the coil 50 has a concave or convex shape in the axial center direction (radial direction of the stator core) of the spiral structure according to the shape of the stator core 60, that is, as shown in FIG. The peripheral end may be formed in a curved shape that is not flush with the outer peripheral end.

  FIG. 14 is a diagram in which the calorific values of the coil 50 of the present embodiment and a coil (round wire coil) formed by winding a round wire are measured and compared. With respect to the round wire coil and the coil 50 of the present embodiment, the amount of heat generation (temperature) over time was measured at 5 V and 20 A.

  The experiment was stopped because the temperature of the round coil rapidly increased to 28.5 ° C. at 10 seconds and 42 ° C. at 30 seconds, and increased to 73 ° C. at 90 seconds from the start. On the other hand, the coil 50 (20A) of the present embodiment gradually rises in temperature to 21.1 ° C. in 10 seconds and 21.5 ° C. in 30 seconds, and becomes saturated at 32.4 ° C. after 1530 seconds from the start. became.

  As is clear from this result, the coil (the coil whose inner peripheral side is a substantially right angle (inner peripheral right-angle coil)) 50 of the present embodiment has a temperature close to normal temperature (for example, 40 ° C. to 50 ° C.) or more even during operation. It can be said that there is almost no temperature rise, and that the heat dissipation is very high. With such high heat dissipation, the coil resistance can be significantly reduced as compared with the related art.

  Further, the width W3 of the start end portion and the end portion of the spiral structure of the coil 50 may be wider than the width W1 in the widthwise direction. Thereby, similarly to the corners, the coil resistance at the start end and the end can be reduced.

  In the present embodiment, the coil 50 having an inner peripheral right angle formed by repeatedly joining the end faces of the coil pieces by cold pressure welding has been described. However, the present invention is not limited to this, and the end faces of the coil pieces may be joined by another joining method. Specifically, various connection methods such as ultrasonic welding (high-frequency welding), electric welding, and brazing can be adopted.

<How to attach to stator core>
With reference to FIG. 15, an example of attaching the coil 50 of the present embodiment to the stator core will be described. FIG. 15A is a side view of the coil 50 and the cassettes 51A and 51B. FIG. 15B is a cross-sectional view taken along the line cc of FIG. 15A. FIG. 15C is a cross-sectional view illustrating an example of attachment to the stator core 60 and corresponding to a cross-section taken along line cc of FIG.

  The coil 50 of the present embodiment is formed along the outer shape of the stator core as shown in FIG. 13C, and is integrally coated with an insulating resin after the molding, and is mounted on the stator core by so-called retrofit.

  Therefore, for example, as shown in FIG. 2A, two cassettes 51A and 51B having flanges 52A and 52B on one surface side in the axial center direction of the spiral structure of the coil 50 are prepared, and one of the cassettes 51A is provided. The coil 50 is inserted from the side where the flange 52A is not formed, and the other cassette 51B is overlapped and engaged with the other. Then, the cassette-equipped coil 50 is inserted into the stator core 60. The cassettes 51A and 51B are provided with notches or engagement portions 53 so as to be fitted in the cross section shown in FIG.

  In addition, as shown in FIG. 3C, the coil 50 may be attached to one cassette 51C having a flange portion 52B only on one surface side in the axial center direction of the spiral structure, and attached to the stator core 60. In this case, in order to prevent the coil 50 from coming off (or generating unnecessary movement (vibration)) from the stator core 60 due to the centrifugal force during operation, a notch 61 is provided in the stator core 60, and the cassette-equipped coil 50 is connected After being attached to the coil 60, the retaining ring 62 covering the upper part of the coil 50 with a cassette and the notch 61 of the stator core 60 may be fitted.

<Coil spiral structure>
The spiral structure of the coil will be further described with reference to FIGS. 16A and 16B are side views of the coil 50 of the present embodiment. FIG. 16A is a side view of one example viewed from the short side, and FIG. 16B is a view of the coil 50 viewed from the long side. FIG. 4C is a side view of another embodiment viewed from the short side, and FIG. 5D is a side view of the other embodiment viewed from the long side. Is a side view of another embodiment viewed from the short side. FIGS. 17A and 17B are modified examples of FIGS. 16C and 16E. FIGS. 17A and 17C are external perspective views, and FIGS. It is an arrow side view of (a) and (c).

  For example, when a plurality of U-shaped (U-shaped) unit coil pieces shown in FIG. 6 are connected to form a spiral structure, a first spiral is formed as shown in FIGS. During one rotation from the rotation TC1 to the second rotation TC2, the coil is gradually deformed in the spiral traveling direction to absorb the thickness of the unit coil piece, and this is repeated for each rotation.

  That is, the coil 50 according to one example of the present embodiment is strictly connected to the next coil piece while each coil piece is slightly inclined, as shown in FIGS. A spiral structure is formed. Here, one side of the short side of the coil 50 (FIG. 10A) and one side of the long side (FIG. 10B) are shown, but the same applies to all four sides of the coil 50. Incline.

  Further, the coil 50 of the present embodiment is not limited to the above structure, and may have a spiral structure as shown in FIGS.

  That is, as shown in FIG. 3C, a part of the first circumference TC1 of the spiral of the spiral structure is deformed so that a step B corresponding to the thickness of the coil piece is formed along the spiral traveling direction. A part of the second circumference TC2 of the spiral is deformed so that a step B corresponding to the thickness of the coil piece is formed in the spiral traveling direction, and this is repeated to form a spiral structure. The step B is formed on only one side surface (for example, one side surface on the short side) of the coil 50, and is located on the same position, that is, on the step B of the first periphery. A step B is formed.

  As described above, since the thickness of the coil piece is absorbed by the step B formed on only one side face, as shown in the long side view of FIG. There is no inclination, and they are stacked substantially horizontally.

  According to such a configuration, the outermost coil surface can be flattened without the start end SE and the end end EE of the coil 50 projecting. That is, in the spiral structure of FIGS. 7A and 7B, as shown in FIG. 7A, the surface of the coil 50 including the start end SE (the lower end surface in the drawing) is the coil surface SF12 of the start end SE. There is a level difference between 'and the coil surface SF11 on the opposite side that has circulated, and is not the same surface. Similarly, the surface of the coil 50 including the end end EE (the upper end surface in the drawing) is not flush with the coil surface SF22 'on the side facing the coil surface SF21' of the end end EE, and is not the same surface. When the thickness of the coil piece is relatively small, there is little problem even if such a step occurs. However, when the coil pieces are thick, it is necessary to secure a space for the step difference when setting the cassettes in the cassettes 51A and 51B as shown in FIG. In addition, a problem such as rattling of the coil 50 due to a gap may occur.

  On the other hand, in the helical structure shown in FIGS. 3C and 3D, the surface of the coil 50 including the start end SE (the lower end surface in the drawing) is a coil on the opposite side that circulates around the coil surface SF12 of the start end SE. The surface (the upper end surface in the drawing) of the coil 50 including the end end EE is (substantially) identical to the coil surface SF22 on the side facing the coil surface SF21 of the end end EE. Provided on the surface. Thus, the size of the outer shape of the coil 50 can be reduced, and the adhesion to the cassettes 51A and 51B can be improved.

  FIG. 11E shows another example having the same helical structure as FIGS. 10C and 10D, but having a different shape of the coil piece. The coil piece may have a (substantially) square cross-section in which the width W and the thickness d2 in the band short direction BS are substantially equal, as shown in FIG. When the thickness d2 is larger than the width W, it is more preferable to adopt a spiral structure in which a step B is provided on one side surface of the coil 50 as shown in FIG.

  FIG. 17 is a diagram illustrating another example of the present embodiment. As shown in the figure, all coil pieces (all coil pieces connected along the spiral traveling direction) configuring the coil 50 have different widths W and thicknesses d2 in the short band direction BS. Is also good. For example, in the coil 50 shown in the drawing, the width W of each coil piece gradually increases from the start end SE to the end end EE (WA, WB...) And the thickness d2 gradually decreases. Connected.

  Not limited to this example, a configuration in which only the width W of each coil piece is different (changes) or a configuration in which only the thickness d2 of each coil piece is different (changes) may be used.

  In this way, a desired quadrangular pyramid coil 50 can be manufactured. Further, when a spiral structure as shown in FIG. 16A is employed particularly when a plurality of coil pieces having different thicknesses d2 are used as in this example, the thickness d2 of the coil piece at the start end SE and the end end EE. , A difference also occurs in the value of the step between the coil surfaces of the outermost periphery (the uppermost outermost periphery and the lowermost outermost periphery in the drawing). As a result, the outer size of the coil 50 increases and the coil 50 becomes non-uniform (asymmetric), so that it is necessary to secure extra space in the cassettes 51A and 51B. In addition, there is a high possibility that steady attachment to the cassettes 51A and 51B becomes difficult. In such a case, a spiral structure in which a step B is formed on one side surface of the coil 50 makes the outermost coil surface (substantially) flat even when the thickness d2 of each coil piece is different. (The coil surfaces SF11 and SF12 can be made the same surface, and the coil surfaces SF21 and SF22 can be made the same surface), so that the size of the coil outer shape 50 can be greatly reduced and the cassettes 51A and 51B can be mounted. Problems during installation can be avoided.

  In the above example, the case where the step B is provided on one side which is the short side of the coil 50 has been described as an example. However, the step B may be provided on one side which is the long side of the coil 50. The position to be provided can be appropriately selected according to the shape of the leading end SE and the end end EE.

  As described above, the present invention is not limited to the above-described embodiment, and can be configured in various embodiments. For example, the bent portion of the coil piece may be curved.

  In addition, one coil piece is not limited to a single copper plate formed by punching, but may include a plurality of narrow rectangular conductors (for example, rectangular conductors having a square cross section in the belt longitudinal direction as shown in FIG. 16E). ) May be arranged in parallel in the width direction of the coil. Further, the coil may be partially formed by a coil piece formed by stamping one copper plate, and partially formed by a coil piece formed by arranging narrow rectangular conductors in parallel.

  INDUSTRIAL APPLICABILITY The present invention can be used, for example, when manufacturing a coil device using a rectangular coil.

DESCRIPTION OF SYMBOLS 10 Cold press apparatus 20 Coil manufacturing apparatus 11 1st holding part 12 2nd holding part 50 Coil

Claims (14)

A coil manufacturing apparatus for forming a spiral structure by joining a plurality of strip-shaped conductors that can be in a spiral shape when being continuous,
The first conductor and the second conductor that can be sandwiched between the conductor and the other conductor and are disposed to face each other, and are movable in a first direction,
The first holding unit and the second holding unit are respectively configured from a first holding body and a second holding body that are movable along a second direction,
One holding body end face composed of one end face of the first holding body and one end face of the second holding body is located in a space inside the spiral structure,
An apparatus for manufacturing a coil, comprising: The holder end surface extends in a direction orthogonal to both the first holding unit and the second holding unit facing surface, and the first holding unit and the second holding unit facing surface. The side to do
The coil manufacturing apparatus according to claim 1, wherein: One of the first holding portion and the second holding portion holds one conductor or a connection body of a plurality of the conductors (hereinafter, referred to as a “leading conductor”),
The other of the first holding unit and the second holding unit holds another of the conductors (hereinafter, referred to as “later conductor”),
In the state where the preceding conductor is deformed in the spiral traveling direction of the spiral structure in at least a part of the region other than the vicinity of the end, the end is connected to the end of the subsequent conductor,
The coil manufacturing apparatus according to claim 1 or 2, wherein: The deformation is an elastic deformation and / or a plastic deformation,
The coil manufacturing apparatus according to claim 3, wherein: The thickness of at least one of the first holding member and the second holding member along the second direction is smaller than an amount allowed for deformation of the preceding conductor.
The coil manufacturing apparatus according to claim 3 or 4, wherein: A plurality of strip-shaped conductors that can be formed into a spiral structure when they are made continuous are prepared, and one conductor or a connection body of the plurality of conductors (hereinafter, referred to as a “first conductor”) is connected to another conductor (hereinafter, a “second conductor”) ") Is a method of manufacturing a coil for connecting
In the state where the preceding conductor is deformed in the spiral traveling direction of the spiral structure in at least a part of the region other than the vicinity of the end, the end is connected to the end of the subsequent conductor,
A method for manufacturing a coil, comprising: The deformation is an elastic deformation and / or a plastic deformation,
The method for manufacturing a coil according to claim 6, wherein: The aforementioned conductor has at least a first side and a second side that are opposite sides in the spiral structure,
When at least a part of the first side is held by the holding unit of the connection device, the second side is shifted to the first side along the axial direction of the spiral structure. So that
The method for manufacturing a coil according to claim 6, wherein: The amount of deformation that shifts the second side with respect to the first side is an amount larger than the thickness of the conductor.
The method for manufacturing a coil according to claim 8, wherein: In a part of the first circumference of the spiral of the spiral structure, the spiral is deformed so that a step corresponding to the thickness of the conductor is formed along the spiral traveling direction, and the second circumference of the spiral of the spiral structure is formed. In some of them, it is deformed so that a step corresponding to the thickness of the conductor is formed along the spiral traveling direction,
The method for manufacturing a coil according to any one of claims 6 to 9, wherein: The end surface of the preceding conductor and the end surface of the subsequent conductor are pressed against each other in the spiral traveling direction,
The method for manufacturing a coil according to any one of claims 6 to 10, wherein: A coil formed of a spiral structure in which a strip-shaped conductor is continuously formed in a spiral shape,
In a part of the first circumference of the helix of the helix structure, the helix is deformed so that a step is formed along the helix traveling direction,
In a part of the second circumference that is continuous with the first circumference, it is deformed so that a step is formed along the spiral traveling direction,
A coil characterized in that: A part of the first circumference and a part of the second circumference are portions constituting the same side surface of the spiral structure,
13. The coil according to claim 12, wherein: A method of manufacturing a coil in which a plurality of strip-shaped flat conductors that can be a spiral structure when continuous are prepared, and the spiral structure is formed by joining end faces of the plurality of the flat conductors,
One end face in the band longitudinal direction of the first flat conductor, and a pressure contact step of pressing and pressing the one end face in the band longitudinal direction of the second flat conductor,
Removing the protruding 7 in a direction intersecting the band longitudinal direction and the band lateral direction by pressing.
A method for manufacturing a coil, comprising:

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