JP4274773B2 - Coil and manufacturing method thereof - Google Patents

Coil and manufacturing method thereof Download PDF

Info

Publication number
JP4274773B2
JP4274773B2 JP2002293091A JP2002293091A JP4274773B2 JP 4274773 B2 JP4274773 B2 JP 4274773B2 JP 2002293091 A JP2002293091 A JP 2002293091A JP 2002293091 A JP2002293091 A JP 2002293091A JP 4274773 B2 JP4274773 B2 JP 4274773B2
Authority
JP
Japan
Prior art keywords
winding
coil
coil winding
portions
wire
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP2002293091A
Other languages
Japanese (ja)
Other versions
JP2004129446A (en
Inventor
喜久 鶴田
Original Assignee
株式会社ワカ製作所
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社ワカ製作所 filed Critical 株式会社ワカ製作所
Priority to JP2002293091A priority Critical patent/JP4274773B2/en
Publication of JP2004129446A publication Critical patent/JP2004129446A/en
Application granted granted Critical
Publication of JP4274773B2 publication Critical patent/JP4274773B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Images

Classifications

    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Description

【０００１】
【発明の属する技術分野】
本発明は、電動車両等に使用されるモータのステータ（固定子）等におけるコイルの製造方法に関し、特に、独特な構造のコイルを製造するための独特な方法に関する。
【０００２】
【従来の技術】
モータは、ロータ（回転子）と、その回りに位置するステータ（固定子）を備えており、ステータ（固定子）は、鉄心回りに、断面が円形の銅線等の金属線を巻いて構成する。
【０００３】
【発明が解決しようとする課題】
しかしながら、従来のステータ（固定子）においては、銅線等の金属線を巻いてコイルを形成しているため、金属線の巻回自体が難しいと共に、巻回されたコイルの形状を保持するのも難しく、コイルを正規の形状に正確に形成するのが困難であり、特に、独特な形状のコイルの形成は極めて困難であった。
【０００４】
本発明は、上記のような課題を解決するためなされたものであり、特に、線材を加工して、鉄心が挿入される複数の筒状の巻線部を設け、この複数の巻線部を有する線材を複数用意して、それぞれ編み込むことで環状に形成したコイルの製造方法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
このため、請求項１に係る発明のコイルの製造方法は、直線状の線材からなり、複数の角部を有する複数のターン部からなり、鉄心が挿入される筒状の巻線部を形成し、該筒状の巻線部の形成を複数回繰り返し行って、複数の巻線部を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成したコイル巻線製造工程と、
前記各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させる平行化工程と、
前記コイル巻線を丸める丸め工程と、
前記コイル巻線の一方の端末を段曲げ加工する端末段曲げ加工工程と、
前記コイル巻線の両端の線部を所定形状に折り曲げ成形した後、所定長さに切断するフォーミング工程と、
前記コイル巻線製造工程、平行化工程、丸め工程、端末段曲げ加工工程及びフォーミング工程によって製造された３つのコイル巻線のうち１つ目のコイル巻線の隣接する巻線部間の一方寄りに２つ目のコイル巻線の巻線部が位置し、１つ目のコイル巻線の隣接する巻線部間の２つ目のコイル巻線の巻線部寄りに３つ目のコイル巻線の巻線部が位置して、巻線部が列状に並ぶように、１つ目のコイル巻線と２つ目のコイル巻線とを交差させて編み込み、かつ、１つ目のコイル巻線と２つ目のコイル巻線とを編み込んで形成したコイル巻線と３つ目のコイル巻線とを交差させて編み込む編み込み工程と、
を含むことを特徴とする。
【０００９】
請求項２に係る発明は、前記コイル巻線製造工程は、直線状の線材を略円形の第１のガイド部材に沿わせて配設した後、該線材の前側を押圧して第１のガイド部材に沿わせて折り曲げ、更に、線材を前方に移動した後、前側を押圧して第１のガイド部材に沿わせて折り曲げ、線材の押圧と移動とを複数回繰り返し行って、複数の角部を有する複数のターン部からなる筒状の巻線部を形成し、前記線材の押圧と移動とを複数回繰り返し行って、筒状の巻線部の形成を複数回繰り返し行って、複数の巻線部を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成することを特徴とする。
【００１０】
請求項３に係る発明は、前記平行化工程は、前記複数の巻線部を有するコイル巻線を、各巻線部が第１の治具のブロックに差し込まれるように第１の治具にセットした後、各ブロックを一方向に傾動させて、各巻線部を傾斜変形させ、各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させることを特徴とする。
【００１１】
請求項４に係る発明は、前記丸め工程は、前記コイル巻線の隣接する巻線部間の各連結線部を凹形の第２のガイド部材と凸形の第３のガイド部材とで挟持して丸めることを特徴とする。
【００１２】
請求項５に係る発明は、前記端末段曲げ加工工程は、前記コイル巻線の一方の端末をプレスによって押圧することを特徴とする。
【００１３】
請求項６に係る発明は、前記フォーミング工程は、前記コイル巻線を、両端の巻線部が第２の治具のブロックに差し込まれるように第２の治具にセットした後、前記両端の巻線部に連なる両端の線部をレバーで所定形状に折り曲げ成形した後、所定長さにカッタで切断することを特徴とする。
【００１４】
請求項７に係る発明は、前記線材は絶縁皮膜付き銅線であり、前記フォーミング工程の後に、コイル巻線の端末部から絶縁皮膜を除去する皮膜除去工程を備えてなることを特徴とする。
【００１５】
請求項８に係る発明は、前記編み込んだコイル巻線の中性点にかしめリングを被せてかしめるかしめ工程と、該かしめ点を半田付け又は溶接する工程と、を含むことを特徴とする。
【００１９】
次に、かかる発明の作用について説明すると、請求項１に係るコイルの製造方法では、コイル化を容易に行うことができ、さらに、コイルを正確に形成しつつ、ひいてはモータの製造性を向上することができる。
【００２０】
請求項２に係る発明では、コイル巻線を容易に正確に、しかも、迅速に製造でき、製造性を向上できる。
【００２１】
請求項３に係る発明では、各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと、容易に変形させることができる。
【００２２】
請求項４に係る発明では、コイル巻線を容易に丸めることができる。
【００２３】
請求項５に係る発明では、コイル巻線の端末を簡単に段曲げ加工できる。
【００２４】
請求項６に係る発明では、コイル巻線の両端の線部を簡単に所定形状に折り曲げ成形できると共に、所定長さに簡単に形成できる。
【００２５】
請求項７に係る発明では、コイル巻線の端末部を簡単に電気的に接続可能とすることができる。
【００２６】
請求項８に係る発明では、編み込まれたコイル巻線同士を結束固定できる。
【００２７】
【発明の実施の形態】
以下、添付された図面を参照して本発明の実施の形態を詳述する。
図１は、本発明に係るコイルの製造方法によって製造されたコイルの一実施形態を示している。
このコイル１は、絶縁皮膜付き銅線等の線材からなる３つのコイル巻線２〜４から構成されている。
【００２８】
図２及び図３に示すように、各コイル巻線２〜４は、それぞれ鉄心が挿入される所定ターン数で筒状の巻線部５が複数個（本実施形態では５つ）略平行に段差なく連なり、かつ、略環状に丸った構成である。
【００２９】
因みに、図２のように、例えば、各コイル巻線２〜４において、巻線部５の間隔は６０°で、各コイル巻線２〜４の内径は、１１５ｍｍである。
【００３０】
そして、図１及び図４に示すように、１つ目のコイル巻線２の隣接する巻線部５間の一方寄りに２つ目のコイル巻線３の巻線部５が位置し、１つ目のコイル巻線２の隣接する巻線部５間の２つ目のコイル巻線３の巻線部５寄りに３つ目のコイル巻線４の巻線部５が位置して、各巻線部５が列状に並ぶように、１つ目のコイル巻線２と２つ目のコイル巻線３とを交差させて編み込み、かつ、１つ目のコイル巻線２と２つ目のコイル巻線３とを編み込んで形成したコイル巻線と３つ目のコイル巻線４とを交差させて編み込んである。
【００３１】
この場合、線材は、上記のように、例えば、絶縁皮膜付き銅線から構成されており、コイル巻線２〜４の端末部から絶縁皮膜が除去されている。
【００３２】
また、編み込まれて組み付けられたコイル巻線２〜４は、その中性点に被せられて、かしめられるかしめリング（図示せず）を備えており、このかしめリングのかしめ点には、半田付け又は溶接が施されている。
【００３３】
次に、かかるコイルを製造する本発明に係るコイルの製造方法の一実施形態について説明する。
【００３４】
このコイルの製造方法は、次の工程からなる。
すなわち、
（１）絶縁皮膜付き銅線等からなる直線状の線材からなり、複数の角部を有する複数（本実施形態では、７つ）のターン部５Ａからなり、鉄心が挿入される筒状の巻線部５を形成し、該筒状の巻線部５の形成を複数回繰り返し行って、複数の巻線部５を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成したコイル巻線製造工程（図５及び図７参照）。
（２）各巻線部５が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させる平行化工程（図６参照）。
（３）各コイル巻線２〜４を丸める丸め工程（図２及び図８参照）。
（４）各コイル巻線２〜４の一方の端末を段曲げ加工する端末段曲げ加工工程。（５）各コイル巻線２〜４の両端の線部を所定形状に折り曲げ成形した後、所定長さに切断するフォーミング工程（図９及び図１０参照）。
（６）コイル巻線製造工程、平行化工程、丸め工程、端末段曲げ加工工程及びフォーミング工程によって製造された３つのコイル巻線２〜４を、１つ目のコイル巻線２の隣接する巻線部５間の一方寄りに２つ目のコイル巻線３の巻線部５が位置し、１つ目のコイル巻線２の隣接する巻線部５間の２つ目のコイル巻線３の巻線部５寄りに３つ目のコイル巻線４の巻線部５が位置して、各巻線部５が列状に並ぶように、１つ目のコイル巻線２と２つ目のコイル巻線３とを交差させて編み込み、かつ、１つ目のコイル巻線２と２つ目のコイル巻線３とを編み込んで形成したコイル巻線と３つ目のコイル巻線４とを交差させて編み込まれる編み込み工程（図１及び図４参照）。
【００３５】
かかる工程通りに具体的にコイル１を製造する手順について説明する。
先ず、図７に示すように、直線状の線材６を略円形の第１のガイド部材７に沿わせて配設した後、該線材６の前側を回転押圧部材８で回転押圧して第１のガイド部材７に沿わせて折り曲げ、更に、線材６を前方に移動した後、前側を押圧して第１のガイド部材７に沿わせて折り曲げ、線材６の押圧と移動とを複数回繰り返し行って、複数の角部を有する複数のターン部５Ａからなる筒状の巻線部５を形成し、線材６の押圧と移動とを複数回繰り返し行って、筒状の巻線部５の形成を複数回繰り返し行って、図５（Ｂ）に示すように、複数の巻線部５を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成する（コイル巻線製造工程）。
【００３６】
次に、前記複数の巻線部５を有するコイル巻線２〜４を、各巻線部５が第１の治具のブロック（図示せず）に差し込まれるように第１の治具にセットした後、各ブロックを一方向に傾動させて、各巻線部５を傾斜変形させ、図６に示すように、各巻線部５が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させる（平行化工程）。
【００３７】
次に、図８に示すように、コイル巻線２〜４の隣接する巻線部５間の各連結線部９を凹形の第２のガイド部材１０と凸形の第３のガイド部材１１とで挟持して丸める（丸め工程）。
【００３８】
そして、コイル巻線２〜４の一方の端末を図示しないプレスによって押圧する（端末段曲げ加工工程）。
【００３９】
さらに次には、図９及び図１０に示すように、コイル巻線２〜４を、両端の巻線部５が第２の治具１２の左右のブロック１３，１４に差し込まれるように第２の治具１２にセットした後、前記両端の巻線部５に連なる両端の線部を、ピン１７，１８で回転可能に支持したレバー１５，１６で所定形状に折り曲げ成形した後、所定長さに図示しないカッタで切断する（フォーミング工程）。
【００４０】
その後、上述した各工程によって製造された３つのコイル巻線２〜４のうち１つ目のコイル巻線２と２つ目のコイル巻線３とを交差させて編み込み、かつ、１つ目のコイル巻線２と２つ目のコイル巻線３とを編み込んで形成したコイル巻線と３つ目のコイル巻線４とを交差させて編み込む。
【００４１】
これにより、１つ目のコイル巻線２の隣接する巻線部５間の一方寄りに２つ目のコイル巻線３の巻線部５が位置し、１つ目のコイル巻線２の隣接する巻線部５間の２つ目のコイル巻線３の巻線部５寄りに３つ目のコイル巻線４の巻線部５が位置して、各巻線部５が列状に並ぶ（図１及び図４参照）。
【００４２】
かかる方法において、本実施形態のように、線材６を絶縁皮膜付き銅線で形成したときには、上記したフォーミング工程の後に、コイル巻線２〜４の端末部から絶縁皮膜を除去する皮膜除去工程を備えるのが好ましい。
【００４３】
また、編み込んだコイル巻線２〜４の中性点に図示しないかしめリングを被せてかしめるかしめ工程と、該かしめ点を半田付け又は溶接する工程と、を設けても良い。
【００４５】
かかるコイルの製造方法によれば、絶縁皮膜付き銅線等からなる直線状の線材６からなり、複数の角部を有する複数のターン部５Ａからなる筒状の巻線部５を形成し、該筒状の巻線部５の形成を複数回繰り返し行って、複数の巻線部５を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成し、その後、各巻線部５が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させ、コイル巻線２〜４の丸め、コイル巻線２〜４の一方の端末を段曲げ加工、コイル巻線２〜４の両端の線部を所定形状に折り曲げ成形、所定長さに切断をそれぞれ行った後、各コイル巻線２〜４を交差させて編み込むようにしたから、コイル化を容易に行うことができ、さらに、コイル１を正確に形成しつつ、ひいてはモータの製造性を向上することができる。
【００４８】
【発明の効果】
以上説明したように、請求項１に係るコイルの製造方法によれば、直線状の線材からなり、複数の角部を有する複数のターン部からなる筒状の巻線部を形成し、該筒状の巻線部の形成を複数回繰り返し行って、複数の巻線部を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成し、その後、各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させ、コイル巻線の丸め、コイル巻線の一方の端末を段曲げ加工、コイル巻線の両端の線部を所定形状に折り曲げ成形、所定長さに切断をそれぞれ行った後、各コイル巻線を交差させて編み込むようにしたから、コイル化を容易に行うことができ、さらに、コイルを正確に形成しつつ、ひいてはモータの製造性を向上することができる。
【００４９】
請求項２に係る発明によれば、コイル巻線を容易に正確に、しかも、迅速に製造でき、製造性を向上できる。
【００５０】
請求項３に係る発明によれば、各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと、容易に変形させることができる。
【００５１】
請求項４に係る発明によれば、コイル巻線を容易に丸めることができる。
【００５２】
請求項５に係る発明によれば、コイル巻線の端末を簡単に段曲げ加工することができる。
【００５３】
請求項６に係る発明によれば、コイル巻線の両端の線部を簡単に所定形状に折り曲げ成形できると共に、所定長さに簡単に形成することができる。
【００５４】
請求項７に係る発明によれば、コイル巻線の端末部を簡単に電気的に接続可能とすることができる。
【００５５】
請求項８に係る発明では、編み込まれたコイル巻線同士を結束固定することができる。
【図面の簡単な説明】
【図１】 本発明に係るコイルの製造方法によって製造されたコイルの一実施形態の斜視図
【図２】 同上のコイルを構成するコイル巻線の平面図
【図３】 同上のコイル巻線における巻線部の構成を示す図で、（Ａ）は平面図、（Ｂ）正面図、（Ｃ）は側面図
【図４】 同上のコイルの内側を示す斜視図
【図５】 丸める前で、段差があるコイル巻線の構成を示す図で、（Ａ）は平面図、（Ｂ）正面図
【図６】 丸める前で、段差がないコイル巻線の構成を示す正面図
【図７】 コイル巻線製造工程を実施する装置の平面図
【図８】 丸め工程を実施する装置の平面図
【図９】 フォーミング工程を実施する装置の平面図
【図１０】 フォーミング工程を実施する装置の平面図[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a coil in a stator (stator) of a motor used in an electric vehicle or the like, and more particularly to a unique method for manufacturing a coil having a unique structure .
[0002]
[Prior art]
The motor includes a rotor (rotor) and a stator (stator) positioned around the rotor, and the stator (stator) is configured by winding a metal wire such as a copper wire having a circular cross section around the iron core. To do.
[0003]
[Problems to be solved by the invention]
However, in the conventional stator (stator), since forming the coil by winding a metal wire such as copper wires, with the winding itself of the metal wire it is difficult to retain the shape of the wound coil However, it is difficult to accurately form a coil in a regular shape , and it is particularly difficult to form a coil having a unique shape.
[0004]
The present invention has been made to solve the above-described problems, and in particular, a wire rod is processed to provide a plurality of cylindrical winding portions into which iron cores are inserted. An object of the present invention is to provide a method for manufacturing a coil formed in an annular shape by preparing a plurality of wire rods and braiding them.
[0008]
[Means for Solving the Problems]
For this reason, the manufacturing method of the coil of the invention according to claim 1 is formed of a linear wire rod, a plurality of turn portions having a plurality of corner portions, and a cylindrical winding portion into which an iron core is inserted is formed. The coil winding formed by repeating the formation of the cylindrical winding portion a plurality of times, each of the winding portions being connected to each other with a predetermined interval and stepped in steps. Manufacturing process,
A parallelizing step in which each winding part is deformed from a continuous state having steps in a step shape to a continuous state without steps in a substantially parallel manner;
A rounding step of rounding the coil winding;
A terminal step bending process for bending one end of the coil winding;
A forming step of bending the wire portions at both ends of the coil winding into a predetermined shape and then cutting it into a predetermined length;
Of the three coil windings manufactured by the coil winding manufacturing process, the parallelizing process, the rounding process, the terminal step bending process, and the forming process, one side between adjacent winding portions of the first coil winding. The winding portion of the second coil winding is located in the first coil winding, and the third coil winding is located near the winding portion of the second coil winding between the adjacent winding portions of the first coil winding. The first coil winding and the second coil winding are crossed and braided so that the winding portions of the wire are located and the winding portions are arranged in a row, and the first coil A knitting process in which a coil winding formed by weaving a winding and a second coil winding and a third coil winding are crossed and knitted,
It is characterized by including.
[0009]
In the invention according to claim 2 , in the coil winding manufacturing process, the linear wire is disposed along the substantially circular first guide member, and then the front side of the wire is pressed to form the first guide. Bend along the member, and further move the wire forward, then press the front side and bend along the first guide member, repeatedly pressing and moving the wire several times, multiple corners Forming a cylindrical winding part having a plurality of turns, repeatedly pressing and moving the wire material a plurality of times, and repeatedly forming the cylindrical winding part a plurality of times. Each of the line portions is formed to have a predetermined interval and to be continuous with a stepped shape.
[0010]
In the invention according to claim 3 , in the parallelizing step, the coil winding having the plurality of winding portions is set in the first jig so that each winding portion is inserted into the block of the first jig. After that, each block is tilted in one direction, each winding part is inclined and deformed, and each winding part is deformed from a continuous state having a stepped shape to a continuous state having almost no step. And
[0011]
According to a fourth aspect of the present invention, in the rounding step, each connecting line portion between adjacent winding portions of the coil winding is sandwiched between the concave second guide member and the convex third guide member. And rounding.
[0012]
The invention according to claim 5 is characterized in that, in the terminal step bending process, one end of the coil winding is pressed by a press.
[0013]
In the invention according to claim 6 , in the forming step, after the coil winding is set on the second jig such that the winding portions at both ends are inserted into the blocks of the second jig, The wire portions at both ends connected to the winding portion are bent into a predetermined shape with a lever and then cut into a predetermined length with a cutter.
[0014]
The invention according to claim 7 is characterized in that the wire is a copper wire with an insulation film, and is provided with a film removal step of removing the insulation film from the terminal portion of the coil winding after the forming step.
[0015]
The invention according to claim 8 is characterized in that it includes a caulking step in which a caulking ring is put on a neutral point of the braided coil winding, and a step of soldering or welding the caulking point.
[0019]
Next, the operation of the present invention will be described. In the method for manufacturing a coil according to claim 1 , the coil can be easily formed, and further, the productivity of the motor is improved while accurately forming the coil. be able to.
[0020]
In the invention according to the second aspect , the coil winding can be manufactured easily and accurately and quickly, and the productivity can be improved.
[0021]
In the invention which concerns on Claim 3 , each coil | winding part can be easily changed from the state which has a level | step difference in a step shape to the state which continues substantially parallel and without a level | step difference.
[0022]
In the invention according to claim 4 , the coil winding can be easily rounded.
[0023]
In the invention according to claim 5 , the end of the coil winding can be easily bent.
[0024]
In the invention according to claim 6 , the wire portions at both ends of the coil winding can be easily bent into a predetermined shape and can be easily formed into a predetermined length.
[0025]
In the invention which concerns on Claim 7 , the terminal part of a coil winding can be electrically connected easily.
[0026]
In the invention according to claim 8 , the knitted coil windings can be bound and fixed.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 shows an embodiment of a coil manufactured by the method for manufacturing a coil according to the present invention.
The coil 1 includes three coil windings 2 to 4 made of a wire material such as a copper wire with an insulating film.
[0028]
As shown in FIGS. 2 and 3, each of the coil windings 2 to 4 has a plurality of cylindrical winding portions 5 (five in the present embodiment) approximately parallel with a predetermined number of turns into which the iron core is inserted. The structure is continuous without steps and rounded in a substantially annular shape.
[0029]
Incidentally, as shown in FIG. 2, for example, in each coil winding 2 to 4, the interval between the winding portions 5 is 60 °, and the inner diameter of each coil winding 2 to 4 is 115 mm.
[0030]
As shown in FIGS. 1 and 4, the winding portion 5 of the second coil winding 3 is located on one side between the adjacent winding portions 5 of the first coil winding 2, and 1 The winding portion 5 of the third coil winding 4 is located near the winding portion 5 of the second coil winding 3 between the adjacent winding portions 5 of the first coil winding 2, and each winding The first coil winding 2 and the second coil winding 3 are crossed and braided so that the line portions 5 are arranged in a line, and the first coil winding 2 and the second coil winding 3 The coil winding formed by weaving the coil winding 3 and the third coil winding 4 are knitted to cross each other.
[0031]
In this case, as described above, the wire is made of, for example, a copper wire with an insulating film, and the insulating film is removed from the end portions of the coil windings 2 to 4.
[0032]
In addition, the coil windings 2 to 4 assembled by braiding are provided with a caulking ring (not shown) that is placed on the neutral point and caulked, and soldering is performed on the caulking point of the caulking ring. Or it is welded.
[0033]
Next, an embodiment of a method for manufacturing a coil according to the present invention for manufacturing such a coil will be described.
[0034]
This coil manufacturing method includes the following steps.
That is,
(1) A cylindrical winding made of a linear wire made of a copper wire with an insulating film, etc., comprising a plurality of (in this embodiment, seven) turn portions 5A having a plurality of corners, into which an iron core is inserted. The wire portion 5 is formed, and the cylindrical winding portion 5 is repeatedly formed a plurality of times. Each of the plurality of winding portions 5 has a predetermined interval and has a stepped shape. Coil winding manufacturing process formed so as to be continuous (see FIGS. 5 and 7).
(2) A parallelizing step in which the winding portions 5 are deformed from a state where they are stepped and connected in a stepped manner to a state where they are connected substantially parallel and without a step (see FIG. 6).
(3) A rounding step for rounding the coil windings 2 to 4 (see FIGS. 2 and 8).
(4) A terminal step bending process in which one terminal of each coil winding 2 to 4 is bent. (5) A forming step of bending the wire portions at both ends of each of the coil windings 2 to 4 into a predetermined shape and then cutting it into a predetermined length (see FIGS. 9 and 10).
(6) Three coil windings 2 to 4 manufactured by a coil winding manufacturing process, a parallelizing process, a rounding process, a terminal step bending process, and a forming process are connected to adjacent windings of the first coil winding 2. A winding portion 5 of the second coil winding 3 is located on one side between the wire portions 5, and the second coil winding 3 between the adjacent winding portions 5 of the first coil winding 2. The winding portion 5 of the third coil winding 4 is located near the winding portion 5 of the first coil winding 2 and the second coil winding 5 so that the winding portions 5 are arranged in a line. A coil winding formed by crossing the coil windings 3 and knitting the first coil winding 2 and the second coil winding 3 and a third coil winding 4 A knitting process of knitting in an intersecting manner (see FIGS. 1 and 4).
[0035]
The procedure for specifically manufacturing the coil 1 according to this process will be described.
First, as shown in FIG. 7, the linear wire 6 is arranged along the substantially circular first guide member 7, and then the front side of the wire 6 is rotated and pressed by the rotary pressing member 8 to be the first. After bending along the guide member 7 and further moving the wire 6 forward, the front side is pressed and bent along the first guide member 7 to repeatedly press and move the wire 6 a plurality of times. Then, the cylindrical winding part 5 composed of a plurality of turn parts 5A having a plurality of corners is formed, and the pressing and movement of the wire 6 is repeated a plurality of times to form the cylindrical winding part 5 As shown in FIG. 5 (B), a plurality of winding portions 5 are formed so as to be continuous with a predetermined interval and stepped in a step shape as shown in FIG. 5B (coil winding). Wire manufacturing process).
[0036]
Next, the coil windings 2 to 4 having the plurality of winding portions 5 were set on the first jig so that each winding portion 5 was inserted into a block (not shown) of the first jig. Thereafter, each block is tilted in one direction to cause each winding portion 5 to be inclined and deformed. As shown in FIG. 6, each winding portion 5 is connected in a step-like manner and connected in a substantially parallel manner without a step. It is transformed into a state (parallelization process).
[0037]
Next, as shown in FIG. 8, the connecting line portions 9 between the adjacent winding portions 5 of the coil windings 2 to 4 are connected to the concave second guide member 10 and the convex third guide member 11. Between and round (rounding process).
[0038]
Then, one end of the coil windings 2 to 4 is pressed by a press (not shown) (terminal step bending process).
[0039]
Next, as shown in FIGS. 9 and 10, the coil windings 2 to 4 are arranged so that the winding portions 5 at both ends are inserted into the left and right blocks 13 and 14 of the second jig 12. After being set in the jig 12, the wire portions at both ends connected to the winding portions 5 at both ends are bent and formed into a predetermined shape by levers 15 and 16 rotatably supported by pins 17 and 18, and then a predetermined length. And cutting with a cutter (not shown) (forming process).
[0040]
Thereafter, the first coil winding 2 and the second coil winding 3 among the three coil windings 2 to 4 manufactured by the above-described processes are crossed and braided, and the first The coil winding formed by weaving the coil winding 2 and the second coil winding 3 and the third coil winding 4 are knitted to cross each other.
[0041]
As a result, the winding portion 5 of the second coil winding 3 is positioned closer to one side between the adjacent winding portions 5 of the first coil winding 2, so that the adjacent one of the first coil winding 2 is located. The winding portion 5 of the third coil winding 4 is located near the winding portion 5 of the second coil winding 3 between the winding portions 5 to be wound, and the winding portions 5 are arranged in a row ( 1 and 4).
[0042]
In such a method, when the wire 6 is formed of a copper wire with an insulating film as in the present embodiment, a film removing step for removing the insulating film from the terminal portions of the coil windings 2 to 4 is performed after the forming process described above. It is preferable to provide.
[0043]
Further, a caulking step for caulking a not-shown caulking ring to the neutral points of the knitted coil windings 2 to 4 and a step for soldering or welding the caulking points may be provided.
[0045]
According to such a coil manufacturing method, the cylindrical winding portion 5 is formed of the linear wire 6 made of a copper wire with an insulating film or the like, and includes a plurality of turn portions 5A having a plurality of corner portions, The formation of the cylindrical winding part 5 is repeated a plurality of times, and the plurality of winding parts 5 are formed so as to be continuous with a predetermined interval and a stepped shape, respectively, Each winding part 5 is deformed from a state of being connected with steps in a stepped manner to a state of being connected substantially in parallel with no steps, rounding of the coil windings 2 to 4, and step bending of one end of the coil windings 2 to 4 Since the wire portions at both ends of the coil windings 2 to 4 are bent into a predetermined shape and cut to a predetermined length, and then the coil windings 2 to 4 are crossed and knitted, so that a coil is formed. In addition, the coil 1 can be accurately formed and eventually It is possible to improve the data of manufacturability.
[0048]
【The invention's effect】
As described above , according to the method for manufacturing a coil according to claim 1 , a cylindrical winding portion made of a plurality of turn portions having a plurality of corner portions is formed, and the tube is formed. The plurality of winding portions are formed so as to be connected with a predetermined interval and stepped in a step shape, and then each winding portion is repeatedly formed. Is deformed from a continuous state with steps in a staircase shape to a continuous state without steps in parallel, rounding the coil winding, stepping one end of the coil winding, and wire portions at both ends of the coil winding Since each coil winding is crossed and knitted after being cut into a predetermined shape and cut into a predetermined length, coiling can be easily performed, and the coil is formed accurately. On the other hand, the productivity of the motor can be improved.
[0049]
According to the second aspect of the present invention, the coil winding can be manufactured easily and accurately and quickly, and the manufacturability can be improved.
[0050]
According to the invention which concerns on Claim 3 , it can deform | transform easily from the state where each coil | winding part has a level | step difference in steps, and is connected in a substantially parallel state without a level | step difference.
[0051]
According to the invention of claim 4 , the coil winding can be easily rounded.
[0052]
According to the invention which concerns on Claim 5 , the end of a coil winding can be easily step-bended.
[0053]
According to the sixth aspect of the present invention, the wire portions at both ends of the coil winding can be easily bent into a predetermined shape and can be easily formed into a predetermined length.
[0054]
According to the invention which concerns on Claim 7 , the terminal part of a coil winding can be electrically connected easily.
[0055]
In the invention according to claim 8 , the knitted coil windings can be bound and fixed.
[Brief description of the drawings]
FIG. 1 is a perspective view of an embodiment of a coil manufactured by a coil manufacturing method according to the present invention. FIG. 2 is a plan view of a coil winding constituting the coil. FIG. It is a figure which shows the structure of a coil | winding part, (A) is a top view, (B) Front view, (C) is a side view [FIG. 4] The perspective view which shows the inner side of a coil same as the above [FIG. 5] Before rounding, FIGS. 7A and 7B are diagrams showing a configuration of a coil winding with a step, where FIG. 7A is a plan view, and FIG. 6B is a front view. FIG. 6 is a front view showing a configuration of a coil winding without a step before rounding. FIG. 8 is a plan view of an apparatus that performs a rounding process. FIG. 9 is a plan view of an apparatus that performs a forming process. FIG. 10 is a plan view of an apparatus that performs a forming process.

Claims (8)

直線状の線材からなり、複数の角部を有する複数のターン部からなり、鉄心が挿入される筒状の巻線部を形成し、該筒状の巻線部の形成を複数回繰り返し行って、複数の巻線部を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成したコイル巻線製造工程と、
前記各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させる平行化工程と、
前記コイル巻線を丸める丸め工程と、
前記コイル巻線の一方の端末を段曲げ加工する端末段曲げ加工工程と、
前記コイル巻線の両端の線部を所定形状に折り曲げ成形した後、所定長さに切断するフォーミング工程と、
前記コイル巻線製造工程、平行化工程、丸め工程、端末段曲げ加工工程及びフォーミング工程によって製造された３つのコイル巻線のうち１つ目のコイル巻線の隣接する巻線部間の一方寄りに２つ目のコイル巻線の巻線部が位置し、１つ目のコイル巻線の隣接する巻線部間の２つ目のコイル巻線の巻線部寄りに３つ目のコイル巻線の巻線部が位置して、巻線部が列状に並ぶように、１つ目のコイル巻線と２つ目のコイル巻線とを交差させて編み込み、かつ、１つ目のコイル巻線と２つ目のコイル巻線とを編み込んで形成したコイル巻線と３つ目のコイル巻線とを交差させて編み込む編み込み工程と、
を含むことを特徴とするコイルの製造方法。It consists of a straight wire, consists of a plurality of turns with a plurality of corners, forms a cylindrical winding part into which an iron core is inserted, and repeats the formation of the cylindrical winding part a plurality of times A coil winding manufacturing process in which a plurality of winding portions are formed so as to be continuous with each other having a predetermined interval and a stepped shape,
A parallelizing step in which each winding part is deformed from a continuous state having steps in a step shape to a continuous state without steps in a substantially parallel manner;
A rounding step of rounding the coil winding;
A terminal step bending process for bending one end of the coil winding;
A forming step of bending the wire portions at both ends of the coil winding into a predetermined shape and then cutting it into a predetermined length;
Of the three coil windings manufactured by the coil winding manufacturing process, the parallelizing process, the rounding process, the terminal step bending process, and the forming process, one side between adjacent winding portions of the first coil winding. The winding portion of the second coil winding is located in the first coil winding, and the third coil winding is located near the winding portion of the second coil winding between the adjacent winding portions of the first coil winding. The first coil winding and the second coil winding are crossed and braided so that the winding portions of the wire are located and the winding portions are arranged in a row, and the first coil A knitting process in which a coil winding formed by weaving a winding and a second coil winding and a third coil winding are crossed and knitted,
The manufacturing method of the coil characterized by including. 前記コイル巻線製造工程は、直線状の線材を略円形の第１のガイド部材に沿わせて配設した後、該線材の前側を押圧して第１のガイド部材に沿わせて折り曲げ、更に、線材を前方に移動した後、前側を押圧して第１のガイド部材に沿わせて折り曲げ、線材の押圧と移動とを複数回繰り返し行って、複数の角部を有する複数のターン部からなる筒状の巻線部を形成し、前記線材の押圧と移動とを複数回繰り返し行って、筒状の巻線部の形成を複数回繰り返し行って、複数の巻線部を、それぞれが所定間隔を有し、かつ、階段状に段差を有して連なるように形成することを特徴とする請求項１記載のコイルの製造方法。In the coil winding manufacturing step, a linear wire is disposed along a substantially circular first guide member, and then the front side of the wire is pressed and bent along the first guide member. After moving the wire forward, the front side is pressed and bent along the first guide member, and the wire is repeatedly pressed and moved a plurality of times, and consists of a plurality of turn portions having a plurality of corner portions. A cylindrical winding portion is formed, the pressing and movement of the wire is repeated a plurality of times, and the cylindrical winding portion is repeatedly formed a plurality of times, each of the plurality of winding portions having a predetermined interval. The method for manufacturing a coil according to claim 1 , wherein the coil is formed so as to be continuous with steps in a stepped manner. 前記平行化工程は、前記複数の巻線部を有するコイル巻線を、各巻線部が第１の治具のブロックに差し込まれるように第１の治具にセットした後、各ブロックを一方向に傾動させて、各巻線部を傾斜変形させ、各巻線部が階段状に段差を有して連なる状態から略平行に段差なく連なる状態へと変形させることを特徴とする請求項１又は２記載のコイルの製造方法。In the parallelizing step, the coil winding having the plurality of winding portions is set on the first jig so that each winding portion is inserted into the block of the first jig, and then each block is moved in one direction. 3. The method according to claim 1 , wherein each winding portion is inclined and deformed, and each winding portion is deformed from a continuous state having a stepped shape to a continuous state without a step in a substantially parallel manner. Coil manufacturing method. 前記丸め工程は、前記コイル巻線の隣接する巻線部間の各連結線部を凹形の第２のガイド部材と凸形の第３のガイド部材とで挟持して丸めることを特徴とする請求項１〜３のうちいずれか１つに記載のコイルの製造方法。The rounding step is characterized in that each connecting line portion between adjacent winding portions of the coil winding is sandwiched between a concave second guide member and a convex third guide member, and rounded. The manufacturing method of the coil as described in any one of Claims 1-3 . 前記端末段曲げ加工工程は、前記コイル巻線の一方の端末をプレスによって押圧することを特徴とする請求項１〜４のうちいずれか１つに記載のコイルの製造方法。The said terminal step bending process process presses one end of the said coil winding by press, The manufacturing method of the coil as described in any one of Claims 1-4 characterized by the above-mentioned. 前記フォーミング工程は、前記コイル巻線を、両端の巻線部が第２の治具のブロックに差し込まれるように第２の治具にセットした後、前記両端の巻線部に連なる両端の線部をレバーで所定形状に折り曲げ成形した後、所定長さにカッタで切断することを特徴とする請求項１〜５のうちいずれか１つに記載のコイルの製造方法。In the forming step, after the coil winding is set on the second jig so that the winding portions at both ends are inserted into the block of the second jig, the wires at both ends connected to the winding portions at both ends are arranged. 6. The method for manufacturing a coil according to claim 1 , wherein the part is bent into a predetermined shape with a lever and then cut into a predetermined length with a cutter. 前記線材は絶縁皮膜付き銅線であり、前記フォーミング工程の後に、コイル巻線の端末部から絶縁皮膜を除去する皮膜除去工程を備えてなることを特徴とする請求項１〜６のうちいずれか１つに記載のコイルの製造方法。The wire is copper wire with an insulating coating, after it said forming step, either one of the terminal portions of the coil winding of claims 1 to 6, characterized in that it comprises a film removal step of removing the insulating film The manufacturing method of the coil as described in one. 前記編み込んだコイル巻線の中性点にかしめリングを被せてかしめるかしめ工程と、該かしめ点を半田付け又は溶接する工程と、を含むことを特徴とする請求項１〜７のうちいずれか１つに記載のコイルの製造方法。8. The method according to claim 1 , further comprising: a caulking step in which a caulking ring is placed on a neutral point of the braided coil winding, and a step of soldering or welding the caulking point. The manufacturing method of the coil as described in one.
JP2002293091A 2002-10-04 2002-10-04 Coil and manufacturing method thereof Expired - Fee Related JP4274773B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2002293091A JP4274773B2 (en) 2002-10-04 2002-10-04 Coil and manufacturing method thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2002293091A JP4274773B2 (en) 2002-10-04 2002-10-04 Coil and manufacturing method thereof

Publications (2)

Publication Number Publication Date
JP2004129446A JP2004129446A (en) 2004-04-22
JP4274773B2 true JP4274773B2 (en) 2009-06-10

Family

ID=32284100

Family Applications (1)

Application Number Title Priority Date Filing Date
JP2002293091A Expired - Fee Related JP4274773B2 (en) 2002-10-04 2002-10-04 Coil and manufacturing method thereof

Country Status (1)

Country Link
JP (1) JP4274773B2 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4713219B2 (en) * 2005-05-17 2011-06-29 本田技研工業株式会社 Stator assembly method
JP5548377B2 (en) * 2009-03-31 2014-07-16 日立オートモティブシステムズ株式会社 Rotating electric machine

Also Published As

Publication number Publication date
JP2004129446A (en) 2004-04-22

Similar Documents

Publication Publication Date Title
US4131988A (en) Method of manufacturing a dynamoelectric field member
JP5901846B2 (en) Armature coil and manufacturing method thereof
JP4460499B2 (en) Manufacturing method of stator of rotating electric machine
US20090261683A1 (en) Stator or rotor for electrical machines, and method for its production
US8091206B2 (en) Method of twisting coil wire to make coil assembly for use in electric rotary machine
JPH048149A (en) Manufacture of stator
JP5729368B2 (en) Segment coil manufacturing method
JP5093363B2 (en) Method and apparatus for forming flat conductive wire used for saddle-shaped distributed winding coil
US11171549B2 (en) Method for forming coil and method for manufacturing stator
JP4274773B2 (en) Coil and manufacturing method thereof
JP3692722B2 (en) Motor stator
JP2004087854A (en) Magnetic device and its manufacturing method
US20210184549A1 (en) Method of making electric machine windings with segmented conductors
WO2013168262A1 (en) Wire bundle and method for manufacturing same
JP3744445B2 (en) Rotating electric machine stator
US20220060092A1 (en) Method for providing shaped rods made from an electrical conductor wire and corresponding shaped rods
JP5942759B2 (en) Coil assembly manufacturing method
JP7432290B2 (en) Manufacturing method of segment coil
US3871070A (en) Method for making winding of smooth-core armature
JP3773833B2 (en) Stator manufacturing method
JP7016829B2 (en) Manufacturing method of collective conductor pieces
JP4474805B2 (en) Coil twist shaping method
JP3869080B2 (en) Manufacturing method of electric wire assembly and electric wire assembly
CA1177870A (en) Field winding and field assembly for dynamoelectric machine and method
JPS62160048A (en) Field coil of dc rotary machine and field coil winding method

Legal Events

Date Code Title Description
A621 Written request for application examination

Free format text: JAPANESE INTERMEDIATE CODE: A621

Effective date: 20051004

A977 Report on retrieval

Free format text: JAPANESE INTERMEDIATE CODE: A971007

Effective date: 20080909

A131 Notification of reasons for refusal

Free format text: JAPANESE INTERMEDIATE CODE: A131

Effective date: 20080924

A521 Written amendment

Free format text: JAPANESE INTERMEDIATE CODE: A523

Effective date: 20081121

TRDD Decision of grant or rejection written
A01 Written decision to grant a patent or to grant a registration (utility model)

Free format text: JAPANESE INTERMEDIATE CODE: A01

Effective date: 20090203

A01 Written decision to grant a patent or to grant a registration (utility model)

Free format text: JAPANESE INTERMEDIATE CODE: A01

A61 First payment of annual fees (during grant procedure)

Free format text: JAPANESE INTERMEDIATE CODE: A61

Effective date: 20090303

R150 Certificate of patent or registration of utility model

Free format text: JAPANESE INTERMEDIATE CODE: R150

FPAY Renewal fee payment (event date is renewal date of database)

Free format text: PAYMENT UNTIL: 20120313

Year of fee payment: 3

LAPS Cancellation because of no payment of annual fees