JP3552121B2 - Method of manufacturing armature coil for rotating electric machine - Google Patents

Description

[0001]
[Industrial applications]
The present invention relates to a method for manufacturing an armature coil of a rotating electric machine, for example, a DC motor, or a rotor including an armature coil manufactured by the manufacturing method.
[0002]
[Prior art]
Conventionally, the rotor of a small DC motor such as a starter has a commutator manufacturing process including molding, an armature coil winding process, a commutator assembly process, and a joining process of joining an armature coil to a commutator piece in order. It is manufactured by implementation.
On the other hand, Japanese Patent Application Laid-Open No. 63-194541 discloses that a brush contact portion extending in the axial direction is partially buried in a surface portion of a mold resin cylinder (insulating material) fitted on a rotating shaft, and a mold resin cylinder is provided. An inner conductor that extends in the axial direction while being inclined in the circumferential direction is embedded in the inside, and extends from one end of the brush contact portion to the outer riser portion in the radial direction, and between the outer riser portion and the armature core, A commutator piece is disclosed in which an inner riser portion extends radially from one end of an inner conductor while being electrically insulated from both. By doing so, the coil end can be omitted.
[0003]
A surface type commutator in which commutator pieces are radially arranged in a radial direction is also known. In the surface type commutator, the commutator piece does not have to be carried on the outer periphery of the mold resin cylinder, which is advantageous in high-speed rotation.
[0004]
[Problems to be solved by the invention]
However, the above-described conventional method for manufacturing a rotor of a rotating electric machine has a problem in that the manufacturing steps are complicated and diversified as described above, and automation is not easy due to continuous skilled work.
In the conventional rotor described above, the coil end of the armature coil is axially expanded from the armature core, so that an increase in space is inevitable, and a large centrifugal force is applied to this coil end. Since the commutator mold resin tube fitted on the rotating shaft carries the commutator piece on its outer periphery, it has a disadvantage that measures must be taken. Inherently has the disadvantage of being inferior. In other words, the mold resin tube carrying the commutator piece on its outer periphery must hold the commutator piece against its centrifugal force, and furthermore, the effect of resistance heat of the commutator piece and frictional heat generated by the brush. Large thermal and mechanical loads.
[0005]
In the surface type commutator described above, the surface type commutator is disposed from the end face of the armature core through the coil end accommodating space of the coil in order to bend the coil at a required pitch, and a brush is further laterally provided outside the commutator. However, there is a problem that the axial length, the physique, and the weight of the motor increase. In addition, there is a problem that high-speed rotation of the motor is limited by centrifugal force applied to the coil end.
[0006]
Furthermore, since the commutator piece of the above publication has a large-diameter riser portion, the centrifugal force of the commutator piece proportional to the radius is significantly increased compared to the conventional art, and the load on the mold resin cylinder that supports it is large, Includes the problem that the motor cannot rotate at high speed. Further, the commutator piece, that is, both the brush contact portion and the inner conductor, must be supported in two stages in the radial direction in the mold resin cylinder, and the burden on the mold resin cylinder becomes more severe than in the conventional case. I have. In addition, since the frictional heat generated at the brush contact portion due to friction with the brush must be transmitted to both riser portions, the temperature of the mold resin tube supporting the brush contact portion and the inner axial conductor portion becomes considerably high. I will. Furthermore, since the inner conductor must be obliquely provided in the circumferential direction, there is a disadvantage that the axial length of the molded resin cylinder cannot be shortened.
[0007]
In view of the above-mentioned problem, the present inventors extend a coil side housed in a slot formed on the outer peripheral surface of an armature core of a DC motor, and extend substantially perpendicularly to a rotation axis along an end face of the armature core. After the coil side is accommodated in the slot, the radial outer end of the coil end is joined to the end of the coil side, and the radial inner end of the coil end is further bonded to the slot. Developed a technology to form an armature coil of a rotating electric machine by joining to the radial inner end of another coil end (hereinafter, this type of armature coil is also referred to as a disc-shaped coil end type armature coil). Filed. This armature coil has many advantages, as described below.
[0008]
However, in the above-described disc-shaped coil end type armature coil, in order to individually join a large number of coil ends to the coil sides, it is necessary to first accurately position them, and the coil sides are regulated by slots. It is easily held in a predetermined spatial position. However, it is not easy to accurately position and hold a large number of coil ends at the time of the joining, and it is presumed that a complicated positioning mechanism or procedure is required.
[0009]
Of course, it is possible to integrate the coil side and the coil end in advance, but a bending step is required, and it becomes difficult to insert the coil side into the slot from the axial direction, and the slot opening is sufficiently wide. The serious problem of having to use slots arises.
SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and one object thereof is to provide a method of manufacturing a disk-shaped coil end type armature coil in which positioning of each coil end is easy before joining a coil side and a coil end. It is in.
[0010]
Another object of the present invention is to provide a disc-shaped coil end type armature which can insert a coil side into a slot in the axial direction and can easily position each coil end before joining the coil side to the coil end. An object of the present invention is to provide a method for manufacturing a coil.
[0011]
[Means for Solving the Problems]
According to a first configuration of the present invention, an upper coil side and a lower coil side each formed of a conductor housed in a slot formed on an outer peripheral surface of an armature core of a rotating electric machine and having both ends protruding from both ends of the slot; A lower coil end electrically connected to an end of the lower coil side, and a lower coil end formed of a conductor extending in a radial direction, and a radial outer end electrically connected to an end of the upper coil side. Upper coil end portion made of a conductor that is electrically connected and extends radially inward, and a radial outer end portion of the lower coil end portion and a radial inner end portion of the upper coil end portion are electrically connected. A method for manufacturing an armature coil of a rotating electric machine that is connected,
A predetermined number of lower coil ends arranged in a disk shape with a substantially spiral or substantially radially extending separation groove interposed therebetween, and the lower coil ends formed integrally with the lower coil ends. To form an inner disk consisting of a connecting piece that connects
A predetermined number of upper coil ends arranged in a disc shape with a substantially spiral or substantially radially extending separation groove interposed therebetween; and the upper coil ends formed integrally with the upper coil ends. To form an outer disk consisting of a connecting piece that connects
After the inner disk is fitted to the rotating shaft fitted to the armature core, the outer disk is further fitted, and a radially outer end of the upper coil end and an end of the upper coil side are provided. And connecting the radial outer end of the lower coil end and the end of the lower coil side, connecting the radial inner ends of both coil ends, and then connecting the connecting piece RemoveThereby, the end of the upper coil also serves as a commutator pieceIt is characterized by:
[0012]
The present invention2In the first configuration, each of the slots accommodates a pair of the upper coil side and the lower coil side, and each of the upper coil end and the lower coil end is twice the number of the slots. It is characterized by being formed by the number equal to.
[0013]
The present invention3Is characterized in that, in the first configuration, the connecting piece is formed at an inner peripheral end of the inner disk and an outer peripheral end of the outer disk.
The present invention4Is characterized in that, in the first configuration, the connecting piece has a wheel plate shape.
[0014]
The present invention5In the first configuration, the lower coil end portion on one end side of the armature core, the lower layer coil side, the upper layer coil end portion on one end side of the armature core, and the upper layer coil side may be further configured as follows. The coil conductor is formed integrally to form a substantially one-turn coil conductor, and the lower and upper coil ends at the other end of the armature core are constituted by the inner disk and the outer disk. And
[0015]
The present invention6In the first configuration, the lower coil end on one end side of the armature core is formed integrally with the lower coil side, and the upper coil end on one end side of the armature core is The end of the lower coil and the end of the upper coil on the other end side of the armature iron core are formed integrally with the upper coil side, and are characterized by being constituted by the inner disk and the outer disk.
[0016]
The present invention7Is characterized in that, in the above-mentioned first configuration, a pair of the inner disk and the outer disk is further fitted on both sides of the armature core.
The present invention8The upper coil side and the lower coil side which are accommodated in slots formed on the outer peripheral surface of the armature iron core of the rotating electric machine and whose both ends are made of a conductor protruding from both ends of the slots, and the radial outer end is A lower coil end portion made of a conductor electrically connected to an end portion of the lower coil side and extending in a radial direction, and a radial outer end portion electrically connected to an end portion of the upper coil side. An upper coil end portion made of a conductor extending radially inward, and a rotation formed by electrically connecting a radial outer end portion of the lower coil end portion and a radial inner end portion of the upper coil end portion. A method for manufacturing an armature coil of an electric machine,
A predetermined number of lower coil ends arranged in a disk shape with a substantially spiral or substantially radially extending separation groove interposed therebetween, and the lower coil ends formed integrally with the lower coil ends. Punching out the inner disk consisting of the connecting piece that connects
A predetermined number of upper coil ends arranged in a disc shape with a substantially spiral or substantially radially extending separation groove interposed therebetween; and the upper coil ends formed integrally with the upper coil ends. Punching out the outer disk consisting of the connecting piece that connects
After attaching an insulating connecting member made of an electrically insulating thin plate or film to each lower coil end of the inner disk, the connecting piece is removed to form an inner disk without a connecting piece,
After attaching an insulating connecting material made of an electrically insulating thin plate or film to each upper coil end of the outer disk, the connecting piece is removed to form an outer disk without a connecting piece,
After the inner disk is fitted to the rotating shaft fitted to the armature core, the outer disk is further fitted, and a radially outer end of the upper coil end and an end of the upper coil side are provided. To connect the radial outer end of the lower coil end and the end of the lower coil side, and connect the radial inner ends of both coil ends.Thereby, the end of the upper coil also serves as a commutator pieceA method for manufacturing an armature coil of a rotating electric machine, characterized in that:
[0017]
The present invention9The configuration of the above8Further, the inner disk and the outer disk are attached to both surfaces of the insulating connecting member.
[0018]
[Action and effect of the invention]
In the first configuration of the present invention, since the coil end of the armature coil is configured by the upper coil end and the lower coil end joined to each other at the radial inner ends, the following effects are obtained.
First, since the armature coil has the above structure, the axial dimension of the coil end, which is a coil end portion, is short, so that the size and weight of the motor can be reduced or reduced, and the conventional substantially cylindrical coil end can be used. As compared with the above, the deflection and the like at the time of high-speed rotation are reduced, so that the high-speed rotation realizes a small and large output.
[0019]
In addition, since the coil end is configured by connecting the end located on the smaller diameter side of the half-turn coil conductor to the similar end of the other coil conductor to form an armature coil, the coil structure is extremely simple, The coil conductor of each half turn can be formed only by pressing and bending, and the complicated winding work on the conventional armature core can be omitted, so that the manufacture and assembly of the armature coil is much easier than before. .
[0020]
Furthermore, since each coil end joined in a disk shape by the connecting piece is individually joined to the end of each coil side, the connecting piece is cut off, so that the lower coil end and the upper coil end are cut off. Relative positioning becomes extremely simple. That is, by setting the positions of the disks, the positions of the ends of all the coils can be adjusted.
Further, the coil side is not inserted into the slot in the axial direction, so that the adoption of the odd-shaped slot can be avoided.
[0021]
Note that the connection between the connecting piece and the coil end may be tentatively connected. The present inventionThen furtherSince the upper coil end also serves as a commutator piece, the axial length of the rotating electric machine can be further reduced, and the conventional cylindrical commutator can be omitted.
The present invention2In the configuration, the armature coil structure can be further simplified in the first configuration.
[0022]
That is, the upper coil side of one end of the armature core, the lower coil end of the one end, the lower coil end, the lower coil end of the other end of the armature core, the upper coil end of the other end, the upper layer An armature coil for one turn is formed by the coil side, and a predetermined number of armature coils can be formed by connecting the above configuration repeatedly.
The present invention3According to the configuration, in the first configuration, the connecting piece portion is further formed on the inner peripheral end of the inner disk and the outer peripheral end of the outer disk, so that they can be easily cut off.
[0023]
The present invention4According to the structure of the first aspect, the connecting piece has a wheel plate shape in the first structure, so that it is easy to cut them off. That is, the wheel plates can be cut off at once. Further, since the connecting pieces are located at the same position in the radial direction of the rotating shaft, the cutting may be performed sequentially while rotating the rotating shaft.
The present invention5In the configuration of the first aspect, the lower coil end, the upper coil end, the lower coil side, and the upper coil side of one end of the armature core are further integrally formed. The connection between the coil side and the coil end can be halved while securing the advantage of being able to be inserted in the direction.
[0024]
The present invention6In the first configuration, the lower coil end of one end is formed integrally with the lower coil side, and the upper coil end of one end is formed integrally with the upper coil side. Can be reduced by half while securing the advantage that the coil can be inserted into the slot in the axial direction.
The present invention7In the configuration of the first aspect, the pair of the inner disk and the outer disk is further fitted to both sides of the armature core in the first configuration, so that the bending process of the lower coil side and the upper coil side can be omitted. .
[0025]
The present invention8In the configuration described above, a coil end (referred to as a lower coil end or an upper coil end) is slightly connected to each other by a connecting piece, and is punched out of a conductor plate into a disk shape. After attaching an electrically insulating insulating connecting material and holding each coil end in a disk shape, the connecting piece is removed, and the lower coil end is joined to the lower coil side or the upper coil end and the upper layer are joined. After joining with the coil side, the armature coil is assembled with or without peeling off the insulating connecting material. Therefore, it is easy to align the coil ends at the time of assembly, and then remove the insulating connecting material. Since the process can be omitted, the working process is significantly simplified.
[0026]
The present invention9In the configuration of the ninth configuration, since the inner disk and the outer disk are further bonded and integrated on both surfaces of the insulating connecting material, the work of mounting the disk on the armature core and positioning is performed once. And the process can be further shortened.
[0027]
【Example】
Hereinafter, embodiments of the method for manufacturing an armature coil of a rotating electric machine according to the present invention will be described. These embodiments are examples of application to a rotor of a vehicle starter motor. The starter motor for a vehicle is a normal commutator type DC motor, and its stator structure is well known, so that the description thereof is omitted.
[0028]
(Example 1)
FIG. 1 is an exploded view of the rotor of this embodiment.
Reference numeral 13 denotes a rotor. A laminated armature core 12 is fitted and fixed to a substantially central portion of a shaft 11 formed by forging, cutting, or the like from a bar-shaped steel material. FIG. 2A is an enlarged view of a part of the outer peripheral portion of the armature core 12. A predetermined number of slots 12 a are formed in the outer peripheral portion of the armature core 12 in a substantially axial direction at predetermined intervals in the circumferential direction. As shown in FIG. 3, a coil conductor 14 of an armature coil is disposed near the outer periphery of the armature core 12. The number of the coil conductors 14 is equal to the number of slots of the armature core, and FIG. 3 shows one turn. The coil conductor 14 includes an upper coil side 14a, a lower coil side 14b, and a coil end 14e, which is a so-called coil end for connecting the ends on the anti-commutator side, and these are formed integrally. The distal end of the upper coil side 14a constitutes a fitting portion 14c having a short and small shaft shape, and similarly, the distal end of the lower coil side 14b constitutes a fitting portion 14d having a short and small shaft shape. The upper coil side 14a and the lower coil side 14b of the same coil conductor 14 are inserted axially into a pair of slots 12a separated from each other by a predetermined angle, and the lower coil sides 14b and A pair of upper coil sides 14a are housed vertically. This type of coil conductor 14 can be formed by a normal winding machine using, for example, an electric wire or the like.
[0029]
Next, the lower coil end plate (the inner disk in the present invention) 15 will be described with reference to FIG. The lower coil end plate 15 is formed in a disk shape, and its inner peripheral end is formed of a ring-shaped connecting portion (connecting piece portion) 15a. A connection protrusion 15b having a shape obtained by dividing the cylinder into the same number as the number of slots is provided so as to protrude from the outer peripheral end of the connecting portion 15a in the direction opposite to the armature core in the axial direction. A coil end 15c having a shape obtained by dividing the disk into the same number as the number of slots is provided radially outward from the outer peripheral end of the connecting portion 15a. Each coil end 15c is spirally arranged with a substantially spiral groove d having a constant width, and the lower coil side 14b of the coil conductor 14 is provided near the outer peripheral end of each coil end 15c. A hole (or a notch) 15d into which the fitting portion 14d is fitted is provided.
[0030]
Next, the upper coil end plate (outer disk in the present invention) 16 will be described with reference to FIG. The upper coil end plate 16 is formed in a disk shape, and its outer peripheral end is formed of a ring-shaped connecting portion (connecting piece portion) 16a. A cylinder is formed on the inner peripheral end of the upper coil end plate 16. A connection protrusion 16b of a shape divided into the same number as the number of slots is provided so as to project in the axial direction opposite to the armature core. A coil end 16c having a shape obtained by dividing the disk into the same number as the number of slots is disposed radially inward from the inner peripheral end of the connecting portion 16a. Each coil end 16c is spirally arranged with a substantially spiral groove having a constant width, and the upper coil side 14a of the coil conductor 14 is fitted near the outer peripheral end of each coil end 16c. A hole (or a notch) 16d into which the portion 14c is fitted is provided.
[0031]
The lower coil end plate 15 and the upper coil end plate 16 are formed from a good conductive material such as copper by a processing method such as forging, pressing, and cutting.
Next, a manufacturing process of the rotor will be described with reference to FIG.
First, the armature core 12 is subjected to insulation treatment, and the same number of coil conductors 14 as the number of slots are inserted into the slots 12a from the anti-brush side (also referred to as the anti-commutator side) in the axial direction.
[0032]
Next, the lower coil end plate 15 is loosely fitted to the rotating shaft of the armature core 12, and the fitting portions 14d of the respective coil conductors 14 are individually press-fitted into the holes 15d of the lower coil end plate 15, so that all the coil conductors 14 The lower coil side 14b is individually joined to each lower coil end 15c of the lower coil end plate 15. FIG. 6 shows this joining state.
[0033]
Next, the upper coil end plates 16 are loosely fitted to the rotation shafts of the armature iron cores 12, and the fitting portions 14c of the respective coil conductors 14 are individually press-fitted into the holes 16d of the upper coil end plates 16 so that all the coil conductors 14 The upper coil side 14a is individually joined to each upper coil end 16c of the upper coil end plate 16. This joining state is shown in FIG.
[0034]
Next, the upper coil end plate 16 and the lower coil end plate 15 are joined. After the plates 15 and 16 are joined to the coil conductor 14, as shown in FIG. 7, the connection protrusions 15b and the connection protrusions 16b are arranged so as to overlap in the radial direction. , And 16b are joined by TIG welding or the like for each pair equal to the number of slots.
[0035]
Next, the connection portions 15a and 16a are removed. That is, a cylindrical rotating grindstone whose outer peripheral surface is reduced in diameter toward the distal end side is axially inserted between the connecting portion 15a and the rotating shaft 11 from the right side in FIG. 7, and the connecting portion 15a is shaved off. . Similarly, a cylindrical rotary grindstone having an inner peripheral surface whose diameter increases toward the distal end is inserted in the axial direction from the right side to the outside of the connecting portion 16a in FIG. 7, and the connecting portion 16a is shaved off. For this reason, it is preferable to form the connecting portion 15a as narrow as possible without interfering with the connection of the coil end portions 15c. Thus, the assembly of the armature coil 14 to the armature core 12 is completed. In addition, the connection part 15a and the connection part 16a may be removed by cutting.
[0036]
(Example 2)
A second embodiment, which is a modification of the first embodiment, will be described below with reference to FIG.
This embodiment differs from the coil conductor 14 of the first embodiment in the configuration of the coil conductor 24. That is, the coil conductor 14 of the first embodiment has the same number as the number of slots, and the upper coil side 14a, the lower coil side 14b, and the coil end 14e are integrally formed in a substantially U shape. In this embodiment, coil conductors 24 and 25 are used instead of the coil conductor 14. The coil conductor 24 includes a lower coil side 24a and a lower coil end 24b, and the coil conductor 25 includes an upper coil side 25a and an upper coil end 25b. As shown in FIGS. 9 and 10, each of the coil conductors 24 and 25 is formed of a substantially L-shaped conductor, and is formed by a normal winding machine using electric wires and the like. The radial inner end of the coil end 24b and the radial inner end of the coil end 25b are joined by, for example, welding. Further, the embodiment is different from the embodiment in that the tip of the lower coil side 24a is joined to the lower coil end of the lower coil end plate 26, and the tip of the upper coil side 25a is joined to the upper coil end of the upper coil end plate 27. Same as 1
[0037]
In this embodiment, the lower coil side 24a and the upper coil side 25a are pushed into the slot 120 from the outer peripheral side of the wide opening (open type) slot 120, and then the claw portions 220 of the armature core 22 on both sides of the slot 120 are formed. Is moved down to the slot opening closing side.
What is important in this embodiment is not shown in FIG. 8, but a lower coil end plate 26 corresponding to the lower coil end plate 15 of the first embodiment is shown in FIG. 11 instead of the hole 15d of the first embodiment. As described above, the upper coil end plate 27 corresponding to the upper coil end plate 16 of the first embodiment has one cutout groove 26d on the outer periphery of each lower coil end 26c for each lower coil end 26c. As shown in FIG. 12, one notch groove 27d is provided on the outer periphery of each upper coil end 27c instead of one hole 16d. It is to be noted that 26b and 27b are connection protrusions, and 26a and 27a are connection portions, as in the first embodiment.
[0038]
The manufacturing sequence of the rotor will be described below with reference to FIG.
After the armature core 22 is subjected to insulation treatment, the coil conductors 24 are mounted one by one in each slot 120. Next, the lower coil end plate 26 is loosely fitted on the rotating shaft 11, and the tip of the coil conductor 24 is fitted and fixed in the groove 26d. This state is shown in FIG.
[0039]
Next, one coil conductor 25 is attached to each slot 120. Next, the upper coil end plate 27 is loosely fitted on the rotating shaft 11, and the tip of the coil conductor 25 is fitted and fixed in the groove 27d. FIG. 14 shows the state after mounting.
Next, the radial inner end of the coil end 24b of the coil conductor 24 and the radial inner end of the coil end 25b of the coil conductor 25 are joined by welding or the like.
[0040]
Next, the lower coil end plate 26 and the upper coil end plate 27 are joined by welding. Since this bonding itself is the same as in the first embodiment, the description is omitted.
Next, the joint portion is cut or worn as in the first embodiment to obtain an armature.
(Example 3)
A third embodiment, which is a modification of the first embodiment, will be described below with reference to FIG.
[0041]
In this embodiment, the coil conductor 14 of the first embodiment is replaced by a coil conductor 34 forming a lower coil side (see FIG. 16), a coil conductor 35 forming an upper coil side (see FIG. 17), and a lower coil end plate on one side. 15 and one upper coil end plate 16 on one side.
That is, in this embodiment, a pair of plates 15 and 16 described in the first embodiment are disposed on both sides of the armature iron core 12, respectively, and they are linear coil conductors only forming the upper coil side or the lower layer coil side. 34 and 35. The coil conductors 34, 35 can be inserted in the slot 12a in the axial direction.
[0042]
The manufacturing sequence of the rotor will be described below with reference to FIG. After the armature core 12 is insulated, the coil conductors 34 are mounted in respective slots (not shown), and then both lower coil end plates 15 are mounted. The coil conductor 35 is fitted into the hole 15d of the coil end plate 15, and then the coil conductor 35 is attached to each slot. This state is shown in FIG.
[0043]
Next, both upper coil end plates 16 are mounted, and both ends of the coil conductor 35 are fitted into the holes 16 d of the upper coil end plate 16. This state is shown in FIG.
Next, the radial inner end of the upper coil end plate 16 and the radial inner end of the lower coil end plate 15 are joined by welding.
[0044]
Thereafter, the connecting portions 15a and 16a are removed by abrasion, cutting, or the like, and the coil ends 15c and 16c are separated to complete an armature coil.
In the above embodiment, the upper coil end 16c also serves as a commutator piece of a surface type commutator.
(Example 4)
Another embodiment will be described with reference to FIGS. FIG. 20 is a schematic side view showing a manufacturing apparatus for the disk-shaped upper coil end plate 16 'having no connecting portion used in this embodiment, and FIG. 21 shows a preliminary punching step and a sticking step using the apparatus shown in FIG. 2 shows a schematic plan shape of the workpiece after finishing. In addition, since the manufacturing apparatus and process of the lower coil end plate 15 'are the same as those of the upper coil end plate 16, illustration and description are omitted. Further, the upper coil end plate 16 having a disc-like connection portion shown in FIG. 21 is the same as that shown in FIG. 1, but is schematically schematically shown as a simple wheel plate.
[0045]
This embodiment is different from the first embodiment shown in FIG. 1 in that the connecting portions (connecting piece portions) 15a and 16a are removed, and instead, the holes or the grooves 15d into which the tips of the lower coil sides are fitted are closed. Each lower-layer coil end 15c is adhered to a wheel-plate-shaped electric insulating material (insulating connecting material) 100 (see FIG. 21) so as not to form a hole or groove 16d in which the tip of the upper coil side is fitted. Each upper coil end 16c is bonded to an electric insulating material (not shown) having the same shape as the electric insulating material 100 in the form of a circular plate so as not to be blocked.
[0046]
Therefore, in this embodiment, the connecting portion 15a is cut off, and the lower coil end plate 15 'in which each lower coil end 15c is integrated with the electric insulating material 100 is attached to the armature core 12 instead. Similarly, the connecting portion 16a is cut off, and instead, a disc-shaped lower coil end plate 16 'in which each lower coil end portion 16c is integrated with an electric insulating material (not shown) is attached to the armature core 12. Is done. In this way, the work of removing the connecting portions 15a and 16a after the armature coil is assembled can be omitted. The electric insulating material 100 can be peeled off after the armature coil is assembled, but there is no problem if it is left as it is. Further, in the above embodiment, the electric insulating materials 100 and 101 are made of an adhesive tape. However, an electrically insulating ring-shaped hard resin thin plate is attached to each lower coil end 15c or each upper coil end 16c with an adhesive. You may attach it. Naturally, when the upper coil end 16c also serves as a commutator piece, it is preferable that this hard resin thin plate be affixed inside the upper coil end 16c. By doing so, the hard resin thin plate can also serve as an interposed electrical insulator for electrically insulating the lower coil end 15c and the upper coil end 16c. Similarly, the hard resin thin plate affixed to the lower coil end 15c can also serve as an electrical insulator interposed between the hard resin thin plate and the end face of the armature core 13.
[0047]
Next, a manufacturing process of the upper coil end plate 16 'having no connecting portion and having the lower coil end portions 15c connected by the electric insulating material 100 will be described below. In addition, the manufacturing process of the lower coil end plate 15 'without the connecting portion is the same, and therefore, the description thereof is omitted.
First, the upper coil end plate 16 connected at the connection portion 16a is punched out of the conductor plate 500 by the press 401 in the same process as in the first embodiment. At this time, it is important that the punched upper coil end plates 16 are connected to the strips 501 on both sides by the connecting portion 502 and further connected to each other by the connecting portion 502 in a line. In FIG. 21, reference numeral 16f denotes a hole into which the rotating shaft 11 is loosely fitted.
[0048]
Next, the conductive plate 500 is sent to the attaching device 402, and the circular plate-shaped electric insulating material 100 is attached to a predetermined position (excluding the hole 16d) of the upper coil end plate 16. That is, this attachment is performed by sending the row of the upper coil end plates 16 connected in one row to the attaching device 402 in one direction.
Next, the upper coil end plate 16 that has left the sticking 402 is sent to the second press machine 403, where the joining portions 16a and 502 are cut off to form one upper coil end plate 16. The upper coil end portions 16c are individually separated, and also separated from the other upper coil end plates 16 and the strips 501 to form upper coil end plates 16 'that can be loosely fitted to the rotating shaft 11. Naturally, the upper coil end portions 16c of the upper coil end plate 16 'cannot be separated from each other by the electric insulating material 100 described above.
[0049]
(Example 5)
Another embodiment will be described with reference to FIG.
In this embodiment, a double-sided adhesion type plate body 600 in which a lower coil end plate 15 is attached to one surface of a substantially ring-shaped electric insulating material 100 and an upper coil end plate 16 is attached to the other surface is rotated. It fits loosely on the shaft 11. Even in this case, the lower coil sides 15c and the upper coil sides 16c of the coil conductors 15 and 16 of the first embodiment and the holes (or grooves) 15d and 16d of the plates 15 and 16 are joined (fitted) without any trouble. can do.
[0050]
The manufacturing process of the double-sided adhesive plate body 300 will be described below.
First, the lower coil end plate 15 'on which the electric insulating material 100 is adhered is formed in the same process as that of the fourth embodiment, and the electric insulating material 100 different from the electric insulating material 100 is adhered in the same process. The coil end plate 16 'is formed. Next, the two electric insulating materials 100 may be bonded together. Of course, the lower coil end plate 15 and the upper coil end plate 16 can be attached to both surfaces of a single electric insulating material. In this way, the step of removing the connecting portions 15a and 16a can be omitted, and the assembling step can be simplified.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view of a rotor according to a first embodiment.
FIG. 2A is an enlarged radial cross-sectional view of an outer peripheral portion of an armature core 12;
(B) is an axial side view of the armature core 12 with a rotating shaft.
FIG. 3 is a perspective view of a coil conductor 14 according to the first embodiment.
FIG. 4A is an axial sectional view of a lower coil end plate 15 of the first embodiment.
(B) is an arrow A view of (a).
FIG. 5A is an axial sectional view of an upper coil end plate 16 of the first embodiment.
(B) is an arrow A view of (a).
FIG. 6A is an axial half-sectional view showing a state immediately after the lower coil end plate 15 of the rotor according to the first embodiment is mounted.
(B) is a radial front view of (a).
FIG. 7A is a half sectional view in the axial direction showing a state immediately after the upper coil end plate 16 of the rotor according to the first embodiment is mounted.
(B) is a radial front view of (a).
FIG. 8 is an exploded perspective view of a rotor according to a second embodiment.
FIG. 9 is a side view of a coil conductor 24 according to the second embodiment.
FIG. 10 is a side view of a coil conductor 25 according to the second embodiment.
FIG. 11A is an axial sectional view of a lower coil end plate 26 according to the second embodiment.
(B) is an arrow A view of (a).
FIG. 12A is an axial sectional view of an upper coil end plate 27 of the second embodiment.
(B) is an arrow A view of (a).
FIG. 13
(b() Is an axial sectional view showing a state immediately after the lower coil end plate 26 of the rotor according to the second embodiment is mounted.
(a() Is a view on arrow A of (b).
(C) is a view on arrow B of (b).
FIG. 14
FIG. 9A is an axial cross-sectional view illustrating a state immediately after the upper coil end plate 27 of the rotor according to the second embodiment is mounted.
(b) Is (a)ofAxial front viewIt is.
FIG. 15 is an exploded perspective view of a rotor according to a third embodiment.
FIG. 16C is a plan view of a coil conductor 34 forming a lower coil side of the third embodiment.
(A) is a top view of the tip part of coil conductor 34 of (c).
FIG. 4B is a view of the coil conductor 34 in FIG.
FIG. 17C is a plan view of a coil conductor 35 forming an upper-layer coil side of the third embodiment.
(A) is a top view of the tip part of coil conductor 35 of (c).
FIG. 3B is a view of the coil conductor 35 in FIG.
FIG.(A)FIG. 14 is an axial half-sectional view showing a state immediately after the lower coil end plate 15 is attached to the lower coil end plate 26 of the third embodiment.
(B) of (a)Axial arrowIt is a front view.
FIG. 19A is an axial half-sectional view showing a state immediately after the upper coil end plate 16 of the rotor according to the third embodiment is mounted.
(B) is a radial front view of (a).
FIG. 20 is a block diagram of an apparatus for manufacturing an upper coil end plate 16 ′ according to the fourth embodiment.
21 is a schematic plan view showing the upper coil end plate 16 (showing a semi-finished product of the upper coil end plate 16 ') to which the electric insulating material 100 is adhered in the apparatus of FIG.
FIG. 22 is an axial (thickness) sectional view showing a composite coil end plate 600 according to a fifth embodiment.

Claims (9)

The upper coil side and the lower coil side, which are accommodated in slots formed on the outer peripheral surface of the armature core of the rotating electric machine and whose both ends are made of conductors protruding from both ends of the slot, and the radial outer end is the lower coil side The lower coil end portion made of a conductor electrically connected to the end portion of the upper coil side and extending radially inward, and the radial outer end portion is electrically connected to the edge of the upper coil side and radially inward. An armature of a rotating electric machine, comprising: an upper coil end portion made of an extending conductor; and a radially outer end portion of the lower coil end portion and a radially inner end portion of the upper coil end portion electrically connected to each other. A method for manufacturing a coil, comprising:
A predetermined number of lower coil ends arranged in a disk shape with a substantially spiral or substantially radially extending separation groove interposed therebetween, and the lower coil ends formed integrally with the lower coil ends. To form an inner disk consisting of a connecting piece that connects
A predetermined number of upper coil ends arranged in a disc shape with a substantially spiral or substantially radially extending separation groove interposed therebetween; and the upper coil ends formed integrally with the upper coil ends. To form an outer disk consisting of a connecting piece that connects
After the inner disk is fitted to the rotating shaft fitted to the armature core, the outer disk is further fitted, and a radially outer end of the upper coil end and an end of the upper coil side are provided. And connecting the radial outer end of the lower coil end and the end of the lower coil side, connecting the radial inner ends of both coil ends, and then connecting the connecting piece A method of manufacturing an armature coil of a rotating electric machine , wherein the end of the upper layer coil also serves as a commutator piece by removing the coil . 2. The slot according to claim 1, wherein each of the slots accommodates a pair of the upper coil side and the lower coil side, and the upper coil end and the lower coil end are each formed by a number equal to twice the number of slots. 3. A method for manufacturing an armature coil of a rotating electric machine. The method for manufacturing an armature coil of a rotating electrical machine according to claim 1, wherein the connecting piece is formed at an inner peripheral end of the inner disk and an outer peripheral end of the outer disk. The method for manufacturing an armature coil of a rotating electric machine according to claim 1, wherein the connecting piece has a plate shape. The lower coil end on one end side of the armature core, the lower coil side, the upper coil end on one end side of the armature core and the upper coil side are integrally formed to form a coil conductor of approximately one turn. The method for manufacturing an armature coil of a rotating electric machine according to claim 1, wherein the lower coil end and the upper coil end on the other end side of the armature core are constituted by the inner disk and the outer disk. The lower coil end at one end of the armature core is formed integrally with the lower coil side, and the upper coil end at one end of the armature core is formed integrally with the upper coil side. The method for manufacturing an armature coil of a rotary electric machine according to claim 1, wherein the lower coil end and the upper coil end on the other end side of the child core are constituted by the inner disk and the outer disk. 2. The method according to claim 1, wherein the inner disk and the outer disk are fitted in pairs on both sides of the armature core. 3. The upper coil side and the lower coil side, which are accommodated in slots formed on the outer peripheral surface of the armature core of the rotating electric machine and whose both ends are made of conductors protruding from both ends of the slot, and the radial outer end is the lower coil side The lower coil end portion made of a conductor electrically connected to the end portion of the upper coil side and extending radially inward, and the radial outer end portion is electrically connected to the edge of the upper coil side and radially inward. An armature of a rotating electric machine, comprising: an upper coil end portion made of an extending conductor; and a radially outer end portion of the lower coil end portion and a radially inner end portion of the upper coil end portion electrically connected to each other. A method for manufacturing a coil, comprising:
A predetermined number of lower coil ends arranged in a disk shape with a substantially spiral or substantially radially extending separation groove interposed therebetween, and the lower coil ends formed integrally with the lower coil ends. Punching out the inner disk consisting of the connecting piece that connects
A predetermined number of upper coil ends arranged in a disc shape with a substantially spiral or substantially radially extending separation groove interposed therebetween; and the upper coil ends formed integrally with the upper coil ends. Punching out the outer disk consisting of the connecting piece that connects
After attaching an insulating connecting member made of an electrically insulating thin plate or film to each lower coil end of the inner disk, the connecting piece is removed to form an inner disk without a connecting piece,
After attaching an insulating connecting material made of an electrically insulating thin plate or film to each upper coil end of the outer disk, the connecting piece is removed to form an outer disk without a connecting piece,
After the inner disk is fitted to the rotating shaft fitted to the armature core, the outer disk is further fitted, and a radially outer end of the upper coil end and an end of the upper coil side are provided. By connecting the radial outer end of the lower coil end and the end of the lower coil side, and connecting the radial inner ends of the two coil ends to the upper coil end. Is a method of manufacturing an armature coil of a rotating electric machine, which also serves as a commutator piece . The method for manufacturing an armature coil of a rotating electric machine according to claim 8, wherein the inner disk and the outer disk are attached to both surfaces of the insulating connecting member.

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