JP2905365B2 - Method for manufacturing armature of rotating electric machine - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to, for example, an armature of a starter motor, and more particularly to a method of manufacturing an armature of a rotating electric machine for insulating a magnetic iron core from a coil and an armature of the rotating electric machine.

[0002]

2. Description of the Related Art As an example of the structure of a conventional armature of a rotating electric machine,
For example, JP-A-62-247736,
JP-A-63-11045, JP-A-63-265
There is one disclosed in Japanese Patent Publication No. 550. Also, the magnetic core and core
An example of an armature structure that considers insulation from the
For interleaving paper to be inserted into the ilend and insulation in the slot
Japanese Unexamined Patent Publication No. Sho 63-31 discloses a method for further preventing insulation failure.
No. 4151, and provided separately from the insulator in the slot
Liner out of magnetic core end face to prevent insulation failure
Japanese Patent Application Laid-Open No. 3-235635,
The insulation inside the unit extends outside the end face of the magnetic core
Japanese Patent Application Laid-Open No. 61-66552 discloses a method for preventing defective edges.
And Japanese Utility Model Laid-Open No. 2-129154.
You. Furthermore, when ultrasonic welding the coil and commutator,
Of the armature to prevent cracks and breakage
As an example of the structure, for example JP-A-55-147952
There is a gazette.

[0003]

However, the above-mentioned known technology has the following problems. Any of the above-mentioned known techniques, when the coil inserted into the slot groove of the steel sheet laminated magnetic core is twisted in the manufacture of the armature, the coil hits the edge of the end face of the magnetic core, and the coil is bent from this point as a starting point, As a result, no consideration is given to the fact that the insulator such as the coil film or insulating paper having a low strength is broken, and as a result, the end face of the magnetic core and the coil come into contact with each other, resulting in poor insulation. In the known technique, the insulator in the slot itself is easily broken by bending, and in the known technique, the liner is easily broken by bending because the breakdown during manufacturing is not considered. Further, in the known art, a coil bent at a point slightly away from the end face of the magnetic core is disclosed, but no specific means is described.

In addition to the above-mentioned known technique, a method of providing an insulating plate having the same shape as the steel plate constituting the steel plate laminated magnetic core or an insulating plate inserted into the space between the slot grooves on the end face of the magnetic core. However, as in the above-mentioned known technology, the insulating plate is generally non-metallic and has a low strength, so that bending or destruction occurs due to the coil twist load at the time of manufacturing the armature, and the end face of the magnetic core contacts the coil. Insulation failure occurs.

An object of the present invention is to provide a method of manufacturing an armature of a rotating electric machine and an armature of the rotating electric machine which can prevent occurrence of insulation failure between a magnetic core and a coil.

[0006] To achieve the above object, according to the present invention, the substantially regular intervals substantially in the axial direction on the outer periphery of the substantially cylindrical is formed in a substantially cylindrical shape by laminating steel sheets of a plurality of substantially disk shaped A magnetic core having a plurality of slot grooves, an armature coil manufactured by twisting a coil member inserted in the plurality of slot grooves at at least one end of the magnetic core, In a rotating electric machine having a commutator provided with a riser to be electrically connected to an outer peripheral portion thereof, wherein the armature is bent along an end face of the magnetic core to an interval between coil members inserted into the plurality of slot grooves. Insert the processing jig and insert the bending jig into the coil
Of the magnetic member from the position of the starting point of the twist bending
Manufacturing the armature of the rotating electric machine, wherein the end portion of the armature coil is manufactured by twisting and bending the coil member by applying to a portion up to the end face position of the iron core, and thereafter removing the bending jig. A method is provided.

Preferably, in the method for manufacturing a rotating electric machine, the thickness of the bending jig is equal to or greater than the thickness t of the disk-shaped steel plate, and a distance from an end face of the magnetic iron core to a starting point of twist bending of the armature coil. A method of manufacturing an armature of a rotating electric machine, wherein an end portion of the armature coil is manufactured so that L is equal to or greater than t.

[0008]

[0009]

In the present invention configured as described above,
The bending jig is connected to the starting point of the twist bending of the coil member.
The end portion of the manufactured armature coil is bent from the twist bending starting point near the end face of the bending jig by twisting the applied coil member from the position where the bending is performed to the end face position of the magnetic core . At this time, even if the insulator is twisted and bent together with the coil member to cause dielectric breakdown, the bending position is separated from the end face of the magnetic core by extracting the bending jig after bending. . Therefore, the armature coil does not come into direct contact with the end face of the magnetic iron core, and the occurrence of insulation failure can be prevented.

Further, by bending the end portion of the armature coil using a bending jig having a thickness equal to or greater than the thickness t of the disk-shaped steel plate, the bending jig has sufficient strength. Even when a twisting load is applied, it does not deform more than a disk-shaped steel plate. Therefore, the coil member is not bent starting from the edge of the steel plate, and the distance L from the end face of the magnetic core to the starting point of the twist bending of the armature coil is ensured to be equal to the thickness of the bending jig, and sufficient insulation is provided. A defect prevention effect is obtained.

[0012]

[0013]

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. A first embodiment of the present invention will be described with reference to FIGS. This embodiment is an embodiment of a method for manufacturing an armature for a starter motor. The armature manufactured by the manufacturing method according to the present embodiment includes, as shown in FIGS.
A substantially U-shaped magnetic core having a cylindrical magnetic core 2 formed by laminating a plurality of disk-shaped steel plates 2a, and a plurality of slot grooves 3 provided at equal intervals in an axial direction on an outer peripheral portion of the magnetic core 2; The upper coil 4a and the lower coil 4b of the mold are inserted into each slot groove 3 via the insulating paper 6, and the upper coil 4a and the lower coil 4b are twisted in opposite directions near the both end surfaces of the magnetic core 2. It is manufactured in.

An essential part of the manufacturing method of the present embodiment is a processing method in which the upper coil member and the lower coil member are twisted to form the upper coil 4a and the lower coil 4b. Hereinafter, the procedure of this processing method will be described in detail. First, the work in which the coil members 54 (the upper coil members 54a and the lower coil members 54b) before being bent have already been inserted into the slot grooves 3 of the magnetic iron core 2 is centered, and along the end face 2A of the magnetic iron core 2. The protector 8 is inserted between the coil members 54.
This state is shown in FIGS. FIG. 2 is a side view of the state where the protector 8 is inserted, and FIG. 3 is an enlarged cross-sectional view near the end face of the armature magnetic core. That is, in FIG. 2, the protector 8 is initially at the position shown by the broken line, and is slid to the left and inserted. At this time, in FIG. 3, the upper coil member 54a on the near side and the lower coil member 54b on the back are in a state in which they appear to be substantially overlapped. Next, the protector 8 is applied and the coil member 54 is twisted and bent. This state is shown in FIG. 4 and FIG. FIG. 4 is a side view of the bending state, and FIG. 5 is an enlarged cross-sectional view near the end face of the armature magnetic iron core. At this time, the upper coil member 54a and the lower coil member 5
4b in opposite directions (for example, as shown in FIG. 5,
The upper coil member 54a on the near side and the lower coil member 5 on the left side
The upper coil 4a and the lower coil 4b are manufactured by twisting (such as 4b to the right). By applying the protector 8, these coils 4 are bent from the twist bending starting point 9a near the upper end surface of the protector 8.

After the coil 4 is produced by twisting, the protector 8 is slid to the right and pulled out. This state is shown in FIGS. FIG. 6 is a side view showing a state where the protector 8 is removed, and FIG. 1 is an enlarged cross-sectional view near the end face of the armature magnetic core. When the protector 8 is removed, the twist bending starting point 9a is located at a position separated from the end face 2A of the magnetic core 2 by a certain distance. At this time, as shown in FIG. 1, the insulating paper 6
The end is twisted starting point 9a from end face 2A of magnetic iron core 2.
(The cuff section 6a in FIG. 14 described later).
Equivalent).

According to the present embodiment configured as described above,
Since the protector 8 is applied and the upper coil member 54a and the lower coil member 54b are twisted and bent, the manufactured coil 4
Is bent from the twist bending starting point 9a near the end face of the protector 8. At this time, insulating paper 6 and enamel coating (not shown) bent twisting together with the upper coil member 54a and the lower coil member 54b twisting bending force
Even though dielectric breakdown at point 9a or near, since overtake the protector 8 after bending the breakdown position is spaced from the end face 2A of the magnetic core, the breakdown positions
The insulation function on the magnetic core end face 2A side is not broken.
Insulated paper 6 and enamel coating ensure that
There is no direct contact between the coil 4 and the end face 2A of the magnetic iron core 2, and the occurrence of insulation failure can be prevented. Therefore, the reliability of the product can be improved.

In the above, the case where the manufacturing method of this embodiment is applied to the twist bending of the coil member 54 on the commutator 5 side of the magnetic core 2 has been described. The twisting of the coil member 54 on the side (see FIG. 15 described later) can be applied, and the same effect is obtained in this case.

A second embodiment of the present invention will be described with reference to FIGS. This embodiment is an embodiment of a method of manufacturing an armature for a starter motor, as in the first embodiment. The difference between the method of manufacturing the armature of the present embodiment and the first embodiment is that when the thickness of one steel plate 2a is t, the thickness T of the protector 8 is
Is greater than or equal to t. Other configurations are first
This is almost the same as the embodiment.

The operation of the manufacturing method of this embodiment will be described below. In this embodiment, as in the first embodiment, the protector 8 is inserted and twisted to form an end portion of the coil 4. If the thickness of the protector 8 is too small, the insulation failure preventing effect is obtained. In this case, in this case, by ensuring that the thickness T of the protector 8 is equal to or greater than a predetermined value, a sufficient insulation failure prevention effect is ensured. Hereinafter, this will be described in detail.

First, as a comparative example of this embodiment, a case where the thickness T of the protector is smaller than the thickness t of the steel plate 102a of the magnetic core will be described with reference to FIGS. 7 is a longitudinal sectional view near the magnetic core end face of the armature before bending, FIG. 8 is a longitudinal sectional view near the magnetic core end face of the armature after bending, and FIG. 9 is a cross-sectional view of FIG. . Although the part numbers are all in the hundreds to distinguish them from the present embodiment, the structure itself of the parts is almost the same.

In FIG. 7, since the protector 108 (thickness T) is thinner and weaker than the steel plate 102a (thickness t), the protector 108 is more greatly deformed than the steel plate by a load caused by twist bending. FIG. 8 illustrates the difference in the amount of deformation in a case where the upper coil member 154a is deformed leftward in the drawing. That is, in FIG.
Towards the deformation amount to the left of the protector 108 than the amount of deformation of the drawing in the left of the steel plate 102a1 of the outermost of 2 a is large. Therefore, the upper coil member 154a is bent by the edge of the protector 108 starting from the point P1 at the beginning of the bending process. However, the protector 108 is greatly deformed and the edge shifts to the left in the drawing. Will be able to bend. Therefore, dielectric breakdown occurs at the point P2, and after the protector 108 is pulled out, the upper coil 104a and the magnetic core 102 may come into direct contact with each other, resulting in insulation failure.

On the other hand, FIGS. 10 to 12 are enlarged sectional views of the armature manufactured by the manufacturing method of the present embodiment. 10 is a vertical cross-sectional view of the vicinity of the magnetic core end face of the armature before bending, FIG. 11 is a vertical cross-sectional view of the vicinity of the magnetic core end face after removing the protector after bending, and FIG. 12 is a cross-sectional view of FIG. FIG. In FIG. 10, a protector 8 having a thickness T is provided.
At this time, the protector 8 is made of, for example, steel, and the protector 8 has sufficient strength because the thickness T is equal to or greater than the thickness t of the steel plate 2a. Is hardly deformed, so that each steel plate 2a under the protector 8 is not deformed (even if the protector 8 is slightly deformed, the steel plate 2a is not deformed more than the steel plate 2a as in the comparative example).
Therefore, the upper coil 4a and the lower coil 4b in FIG.
Is bent from the starting point P near the upper end face of the protector 8, and the distance L from the twist bending starting point P to the end face 2A of the magnetic core 2 is substantially equal to T (that is, larger than t). Becomes Therefore, even if the protector 8 is removed, the upper coil 4a and the lower coil 4b are separated from the end face 2A of the magnetic iron core 2 and do not come into contact with each other, so that insulation failure does not occur.

According to this embodiment configured as described above,
The protector 8 has a sufficient strength since it has a thickness T equal to or greater than the thickness t of the disk-shaped steel plate 2a of the magnetic core, and does not deform more than the steel plate 2a even if a twist load is applied. Therefore, the coil member 54 is not bent starting from the edge of the steel plate 2a, and the end face 2A of the magnetic iron core 2 is not bent.
Distance from to twist bending start point P of the coil 4 L is Ru secured by T equal magnitude (i.e. size greater than t).
Therefore, the insulating paper 6 and the enamel film (not shown) are
Even if the dielectric breakdown occurs at or near the torsion bending starting point P,
The dielectric breakdown position is about T from the end face 2A of the magnetic core 2.
Is separated from the magnetic core end face 2A from the dielectric breakdown position.
Side insulation function is ensured by insulating paper 6 and enamel coating
Therefore, a sufficient insulation failure prevention effect can be reliably obtained.

As in the first embodiment, the coil member 5 on the end coil side of the magnetic iron core 2 (see FIG. 15 described later).
4 can be applied, and the same effect can be obtained in this case.

A third embodiment of the present invention will be described with reference to FIG. This embodiment is an embodiment of an armature for a starter motor manufactured by the method for manufacturing an armature according to the second embodiment. Parts common to the first and second embodiments are indicated by common numbers. The state where the coil of the armature of this embodiment is removed
FIG. 13 shows the entire structure in the state . In FIG.
An armature according to the present embodiment includes a shaft 1 having both ends rotatably supported, and a cylindrical magnetic core 2 fixed to the shaft 1.
A plurality of slot grooves 3 provided at equal intervals in the axial direction on the outer peripheral portion of the magnetic core 2;
and a commutator 5 having an outer peripheral portion a.

FIG. 14 shows a detailed cross section near the connection between the commutator 5 and the magnetic core 2. In FIG. 14, the magnetic core 2 is formed by laminating a plurality of disk-shaped steel plates 2a each having a thickness of t.

A coil 4 covered with an enamel coating (not shown) is inserted into the slot 3 (see FIG. 13). The coil 4 has two turns for the starter motor, and one slot groove 3 has one side portion of the upper coil 4a and the lower coil 4b of the substantially U-shape (that is, the U-shape having the bottom portion as the boundary). One of the two parts (right or left side) is inserted. Opposite portions of the upper coil 4a and the lower coil 4b (the remaining portion of the U-shaped shape on the opposite side from the above) are combined with different coils in separate slot grooves which are shifted by several rows, respectively. Are inserted in two pieces at a time. These upper coil 4a and lower coil 4
b is formed in a shape in which the upper coil 4a and the lower coil 4b are twisted in opposite directions at a twist bending starting point 9a separated by a distance L from the end face 2A of the magnetic core 2, and finally the commutator 5 is formed. Are electrically connected to the riser 5a on the outer peripheral portion of the main body.

An insulating paper 6 is provided between the coil 4 and the magnetic core 2 to insulate these two parts, and the insulating paper 6 is provided before the end face 2A of the magnetic core 2 (left side in the figure).
Is provided with a cuff portion 6a which protrudes.

FIG. 15 shows details of the magnetic core 2 on the end coil side (the side opposite to FIG. 14). In FIG. 15, the coil 4 is configured similarly to FIG. That is, the upper coil 4a and the lower coil 4b are twisted and bent in opposite directions at a twist bending starting point 9b separated from the end face 2B of the magnetic core 2 by a distance L. Coil 4
The end of the insulating paper 6 provided between the magnetic core 2 and
Position between the end face 2B of the iron core 2 and the twist bending starting point 9b
The cuff 6b protrudes forward (to the right in the drawing) from the end face 2B of the magnetic core 2 .

According to the armature of the present embodiment configured as described above, the distance L from the end face 2A of the magnetic core 2 to the twist starting point 9a of the coil 4 and the twist bending of the coil 4 from the end face 2B of the magnetic core 2 The distance L to the starting point 9b is not less than t, and a sufficient distance is always secured between the upper and lower coils 4a and 4b and the magnetic core 2. Therefore, a sufficient insulation failure prevention effect can be obtained.

Although the upper coil member 54a and the lower coil member 54b are substantially U-shaped in the above description, the present invention can be applied to other shapes, for example, W-shaped coil members, and the same effects are obtained.

[0033]

According to the present invention, since the coil member is twisted by applying the bending jig, the end portion of the manufactured armature coil is bent from the twist bending starting point near the end face of the bending jig. ing. At this time, even if the insulator is twisted and bent together with the coil member to cause dielectric breakdown, the bending jig is pulled out after bending, so that the dielectric breakdown position is a position away from the end face of the magnetic iron core. Therefore, the armature coil does not come into direct contact with the end face of the magnetic iron core, and the occurrence of insulation failure can be prevented. Therefore, the reliability of the product can be improved.

Also, since the end portion of the armature coil is bent using a bending jig having a thickness equal to or greater than the thickness t of the disk-shaped steel plate, the bending jig has sufficient strength. Even when a load is applied, it does not deform more than a disk-shaped steel plate. Therefore, the coil member is not bent starting from the edge of the steel plate, and the distance L from the end face of the magnetic core to the starting point of the twist bending of the armature coil is ensured to be equal to the thickness of the bending jig, and sufficient insulation is provided. A defect prevention effect can be obtained.

[0035]

[0036]

[Brief description of the drawings]

FIG. 1 is an enlarged cross-sectional view near the armature magnetic core end face in a method of manufacturing an armature according to a first embodiment of the present invention.

FIG. 2 is a side view of a state where a protector is inserted.

FIG. 3 is an enlarged cross-sectional view near the end face of an armature magnetic iron core.

FIG. 4 is a side view in a bending state.

FIG. 5 is an enlarged sectional view near the end face of the armature magnetic iron core.

FIG. 6 is a side view showing a state where a protector is removed.

FIG. 7 is an enlarged cross-sectional view near the end face of an armature magnetic core in a method of manufacturing an armature according to a comparative example of the present invention.

FIG. 8 is an enlarged sectional view near the end face of the armature magnetic iron core.

FIG. 9 is an enlarged cross-sectional view near the end face of the armature magnetic core.

FIG. 10 is an enlarged cross-sectional view near the armature magnetic core end face in the method of manufacturing an armature according to the second embodiment of the present invention.

FIG. 11 is an enlarged sectional view near the end face of the armature magnetic core.

FIG. 12 is an enlarged sectional view near the end face of the armature magnetic core.

FIG. 13 is an overall structural view of an armature according to a third embodiment of the present invention.

FIG. 14 is a detailed cross-sectional view near the connection between the commutator and the magnetic core.

FIG. 15 is a detailed cross-sectional view of the magnetic core on the end coil side.

[Explanation of symbols]

 2 Magnetic core 2A End face 2B End face 2a Disk-shaped steel plate 3 Slot groove 4 Coil 4a Upper coil 4b Lower coil 5 Commutator 5a Riser 8 Protector (bending jig) 9a, 9b Twist bending starting point 54 Coil member 54a Upper coil member 54b Lower coil member L Distance from end face of magnetic core to twist bending start point P Twist bending start point T Protector thickness t Thickness of disk-shaped steel plate

Continuation of the front page (56) References Japanese Utility Model Sho 57-3350 (JP, U) Japanese Utility Model Sho 58-112076 (JP, U) (58) Fields investigated (Int. Cl. ⁶ , DB name) H02K 15 / 04 H02K 3/04 H02K 3/34

Claims (2)

(57) [Claims] 1. A magnetic having a plurality of formed in a substantially cylindrical shape steel by laminating a substantially disk shape substantially <br/> equally spaced plurality of slots grooves substantially in the axial direction on the outer periphery of the substantially cylindrical An outer peripheral portion including an iron core, an armature coil manufactured by twisting a coil member inserted into the plurality of slot grooves at least at one end of the magnetic iron core, and a riser electrically connected to the armature coil; A method for manufacturing an armature of a rotating electric machine having a commutator provided with: a bending jig inserted along an end face of the magnetic core into an interval between coil members inserted into the plurality of slot grooves;
Twist the bending jig out of the coil members.
From the starting point of the magnetic core to the end face of the magnetic core
A method of manufacturing an armature for a rotating electric machine, comprising twisting and bending the coil member in accordance with the length of the armature, and then removing the bending jig to manufacture an end portion of the armature coil. 2. The method for manufacturing a rotating electric machine according to claim 1, wherein the thickness of the bending jig is equal to or greater than the thickness t of the disk-shaped steel plate, and the starting point of the twist bending of the armature coil from the end face of the magnetic core. A method of manufacturing an armature of a rotating electric machine, wherein an end portion of the armature coil is manufactured such that a distance L to the armature becomes t or more.