JP4438982B2 - Winding coil - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a winding coil suitable for use in electrical equipment such as a motor and a generator.
[0002]
[Prior art]
In general, it is advantageous to reduce the winding resistance of a winding coil used in an electric device such as a motor or a generator as much as possible in order to reduce the loss and size of the electric device. Further, when the winding resistance is large, the temperature rise due to heat generation becomes large, so that there is a problem that an insulating material having high heat resistance must be used.
[0003]
Therefore, the number of winding coils using a rectangular wire that can increase the conductor space factor compared to a round wire having a circular cross-sectional shape that has been conventionally used, and as a result, can reduce the winding resistance (for example, patents). Reference 1).
[0004]
[Patent Document 1]
JP 2002-222724 A
[Problems to be solved by the invention]
However, in such a conventional winding coil, a narrow portion having a relatively narrow width is formed at predetermined intervals with respect to the longitudinal direction of the flat wire, and the flat wire is curved at the narrow portion. Since the winding coil having a small curvature of the curved portion is formed, the cross-sectional area of the narrow portion becomes smaller than the cross-sectional area of the other portion, and a new problem that the winding resistance increases in the narrow portion. Has occurred.
[0006]
[Means for Solving the Problems]
The present invention has been made in view of the drawbacks of such a conventional winding coil, and an object thereof is to provide a winding coil using a rectangular wire having a small winding resistance.
[0007]
In order to achieve the above object, a wound coil according to the present invention is formed by helically cutting a coil base material formed by fitting a plurality of rectangular tube conductors having a cross-sectionally similar shape in a nested manner without gaps. Then, each rectangular tube conductor is formed in a rectangular wire shape, and then the cutting end portion of one rectangular tube conductor formed in the rectangular wire shape and the cutting start end portion of the other rectangular tube conductor are sequentially electrically connected. Connected to each other to form a single conductor, and the axial length of each rectangular tube conductor is shortened toward the outer peripheral side .
[0008]
Further, the winding coil according to the present invention, the coil base material being formed by fitting without a gap plural square tubular conductor which forms the cross section similar shape telescopically, incised spirally each rectangular tube The conductor is formed into a rectangular wire shape, and then the cutting end portion of one rectangular tube conductor and the cutting start end portion of the other rectangular tube conductor formed in a rectangular wire shape are sequentially electrically connected to each other. It is characterized in that it is formed in a conductive wire shape and the length in the axial direction of each of the rectangular tubular conductors is the same .
[0009]
Furthermore, the wound coil according to the present invention is characterized in that the incision end portion and the incision start end portion are electrically connected to each other through a stretchable buffer band .
[0010]
Furthermore, the wound coil according to the present invention is characterized in that the incision end portion and the incision start end portion are electrically connected through a connection line .
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a first embodiment of a wound coil according to the present invention will be described in detail with reference to FIGS.
[0012]
FIG. 1 is a perspective view showing a plurality of rectangular cylindrical conductors 3-1 to 3-4 forming a coil base material 2 as a material of a winding coil 1 as an example of the first embodiment of the present invention. It is. Each of the rectangular cylindrical conductors 3-1 to 3-4 has a similar shape, and an insulating film is applied to the peripheral surface by appropriately selecting a resin such as enamel, polyurethane, or polyester according to the use environment.
The rectangular tube conductor 3-1 is fitted to the inner surface of the rectangular tube conductor 3-2 without a gap, the rectangular tube conductor 3-2 is fitted to the inner surface of the rectangular tube conductor 3-3 without a gap, The rectangular tubular conductor 3-3 has a size that can be fitted to the inner surface of the rectangular tubular conductor 3-4 without a gap.
[0013]
FIG. 2 is a diagram showing a coil base material 2 formed by fitting the rectangular cylindrical conductors 3-1 to 3-4 shown in FIG. Between 3-4, it is hold | maintained in the state electrically insulated by the insulating film given to the surrounding surface.
[0014]
FIG. 3 is a perspective view showing a state in which the coil base material 2 composed of the rectangular tubular conductors 3-1 to 3-4 is being cut in a spiral shape. The formation process of the lines 4-1 to 4-4 and the formation state of the flat wires 4-1 to 4-4 are shown.
Here, the rectangular wire 4-1 is a rectangular tube conductor 3-1, the rectangular wire 4-2 is a rectangular tube conductor 3-2, the flat wire 4-3 is a rectangular tube conductor 3-3, and the rectangular wire. 4-4 is formed by cutting a rectangular tube-shaped conductor 3-4. Further, incision of the rectangular tubular conductors 3-1 to 3-4 uses various types such as a wire cutter, a laser cutter, and a carbide rotary blade depending on the material of the rectangular tubular conductors 3-1 to 3-4.
[0015]
FIG. 4 shows a rectangular shape cut out from the rectangular tube conductors 3-1 to 3-4 after the helical incision of the coil base material 2 including the rectangular tube conductors 3-1 to 3-4 in FIG. The perspective view of the whole lines 4-1 to 4-4 is shown.
[0016]
In FIG. 4, 4A is a circuit start end portion as a cutting start end portion obtained by cutting off the thin portion at the front end, and 4B is a circuit end portion as an incision end portion obtained by cutting out the thin portion at the rear end.
The circuit start end portion 4A is formed by bending the start end portions 4A-1 to 4A-4 of the flat wires 4-1 to 4-4, and the circuit end portion 4B is the end portion 4B of the flat wires 4-1 to 4-4. -1 to 4B-4 are formed by bending.
[0017]
After the rectangular wires 4-1 to 4-4 are formed as shown in FIG. 4, at least the cut surfaces of the rectangular tube conductors 3-1 to 3-4 have a periphery of the rectangular tube conductors 3-1 to 3-4. Apply the same insulation film as applied to the surface. Thereby, even if flat wires contact each other, the insulating state is maintained.
[0018]
Reference numeral 5 denotes a connection line that electrically connects the terminal end 4B-1 of the flat wire 4-1 and the start end 4A-2 of the flat wire 4-2.
Reference numeral 6 denotes a connection line that electrically connects the terminal end 4B-2 of the flat wire 4-2 and the start end 4A-3 of the flat wire 4-3.
7 is a connection line for electrically connecting the terminal end 4B-3 of the flat wire 4-3 and the start end 4A-4 of the flat wire 4-4.
[0019]
As a result, the starting end 4A-1 of the rectangular wire 4-1 to the terminal end 4B-4 of the rectangular wire 4-4 are electrically connected as one conducting wire, and the winding coil 1 is formed.
[0020]
FIG. 5 is a partial cross-sectional perspective view showing an example in which two winding coils 1 </ b> A and 1 </ b> B are mounted on the stator core 8.
[0021]
In FIG. 5, reference numeral 9 denotes a press plate that prevents the winding coils 1 </ b> A and 1 </ b> B inserted into the tooth portion 10 from falling off. The press plate 9 is locked between adjacent tooth portions 10.
[0022]
11 is a connection line for electrically connecting adjacent winding coils 1A and 1B, and the connection line 11 is a terminal end of a rectangular wire 4-4 serving as a winding terminal end of the adjacent winding coil 1A. 4B-4 is connected to the start end 4A-1 of the flat wire 4-1, which is the winding start end of the winding coil 1B.
[0023]
FIG. 6 is a partial cross-sectional perspective view showing another example in which two winding coils 1 </ b> A and 1 </ b> B are mounted on the stator core 8.
[0024]
In FIG. 6, 12 is a buffer band formed between the adjacent winding coil 1A and winding coil 1B. The other configuration is the same as that of the example shown in FIG.
[0025]
In this example, the winding coils 1A and 1B are formed as shown in FIG.
That is, after forming the winding coil 1A, the rectangular wires 4-1 to 4-4 are stretched as they are from the circuit terminating end 4B of the winding coil 1A to the circuit starting end 4A of the winding coil 1B, and then the winding coil 1B. Are formed continuously.
Then, the terminal end 4B-4 of the flat wire 4-4 in the continuously formed winding coil 1A and the start end portion 4A-4 of the flat wire 4-4 in the winding coil 1B are used as the buffer band 12, and both coils 1A, 1B is integrally formed without any electrical loss.
Thereafter, both the coils 1A and 1B are formed so as to be inserted into the tooth portion 10 of the stator core 8 as shown in FIG.
[0026]
Here, the terminal ends 4B-1 to 4B-3 of the rectangular wires 4-1 to 4-3 in the continuously formed winding coil 1A and the starting ends 4A- of the rectangular wires 4-1 to 4-3 in the winding coil 1B. A portion corresponding to the buffer band 12 is excised from 1 to 4A-3.
[0027]
In the other example of this embodiment shown in FIG. 6, the two winding coils 1A and 1B are integrally formed. However, as a configuration in which three or more winding coils are integrally formed, Also good.
[0028]
Thereby, according to the other example of this embodiment shown in FIG. 6, the connection line 11 like one example shown in FIG. 5 becomes unnecessary, and connection failure prevention can be aimed at.
[0029]
Further, by forming the plurality of winding coils 1A and 1B in accordance with the facing angle of the tooth portion 10 to be inserted and the curvature of the stator core 8, the insertion into the tooth portion 10 is facilitated, and the buffer band Since 12 itself is formed to be extendable and retractable, it can be easily and reliably attached to the stator core 8 even if there is some mismatch in curvature.
[0030]
Although the present embodiment is configured as described above, the shapes of the winding coil 1 and the winding coils 1A and 1B are not limited to a rectangular shape, and as shown in FIG. Depending on the shape of the tooth portion or the core, various polygonal shapes, elliptical shapes and the like can be dealt with.
[0031]
Moreover, in this embodiment, although demonstrated as a structure which forms a winding coil using the rectangular tube-shaped conductor which has provided the insulating film on the surrounding surface, it is not limited to this, In a rectangular tube-shaped conductor, May have a configuration in which an insulating film is not applied in advance, and a coil base material is cut in a spiral shape to form a wound coil, and then an insulating film is applied to the entire wound coil using various known film forming means. It is.
[0032]
Next, a second embodiment of the winding coil according to the present invention will be described in detail with reference to FIGS.
[0033]
The difference between this embodiment and the first embodiment is that the axial direction of the rectangular cylindrical conductor that is the material of the winding coil in order to reduce the gap between adjacent winding coils and increase the conductor space factor. The length is shortened toward the outer peripheral side.
[0034]
That is, as shown in FIG. 10, a coil base material 22 which is a material of the winding coil 21 is provided on the outer periphery of the coil base material 2 in the first embodiment with a plurality of corners shorter in the axial direction than the coil base material 2. It is formed by inserting cylindrical conductors 23-1, 24-1.
Here, the coil base material 2 is fitted to the inner surface of the rectangular tube-shaped conductor 23-1 without a gap, and the rectangular tube-shaped conductor 23-1 has a size that can be fitted to the inner surface of the rectangular tube-shaped conductor 24-1 without a gap. It has become.
[0035]
FIG. 11 is a view showing a coil base material 22 formed by fitting the coil base material 2 shown in FIG. 10 and each of the rectangular tubular conductors 23-1 and 24-1 in a nested manner without gaps. And between each square cylindrical conductor 23-1, 24-1, it is hold | maintained in the state electrically insulated by the insulating film given to the surrounding surface.
[0036]
FIG. 12 shows a perspective view of the coil base material 2 and the coil base material 22 made up of each of the rectangular cylindrical conductors 23-1, 24-1 in the middle of being cut in a spiral shape. The formation process of the rectangular wires 4-1 to 4-4, 25-1, and 26-1 forming the coil 21 and the formation state of the rectangular wires 4-1 to 4-4, 25-1, and 26-1 are shown. .
Here, the rectangular wire 25-1 is formed by cutting the rectangular tube conductor 23-1, and the rectangular wire 26-1 is formed by cutting the rectangular tube conductor 24-1.
[0037]
FIG. 13 shows the coil base material 2 and the rectangular cylindrical conductors 23-1 and 24-1 in FIG. 23 is a perspective view of the entire rectangular wires 4-1 to 4-4, 25-1 and 26-1 cut out from 23-1 and 24-1.
[0038]
In FIG. 13, reference numeral 25A denotes a circuit start end portion as a cutting start end portion obtained by cutting off the thin portion at the front end, and reference numeral 25B denotes a circuit end portion as an incision end portion obtained by cutting out the thin portion at the rear end.
The circuit start end portion 25A is formed by bending the start end portion 25A-1 of the flat wire 25-1, and the circuit end portion 25B is formed by bending the end portion 25B-1 of the flat wire 25-1. Similarly, reference numeral 26A denotes a circuit start end portion as a cutting start end portion obtained by cutting off the thin portion at the front end, and 26B denotes a circuit end portion as an incision end portion obtained by cutting out the thin portion at the rear end.
The circuit start end portion 26A is formed by bending the start end portion 26A-1 of the flat wire 26-1, and the circuit end portion 26B is formed by bending the end portion 26B-1 of the flat wire 26-1.
[0039]
A connection line 27 electrically connects the terminal end 4B-4 of the flat wire 4-4 and the start end 25A-1 of the flat wire 25-1.
Reference numeral 28 denotes a connection line that electrically connects the terminal end portion 25B-1 of the flat wire 25-1 and the start end portion 26A-1 of the flat wire 26-1.
[0040]
As a result, the starting end 4A-1 of the flat wire 4-1 and the terminal end 26B-1 of the flat wire 26-1 are electrically connected as one conducting wire, and the winding coil 21 is formed.
[0041]
FIG. 14 is a partial cross-sectional perspective view showing an example in which two winding coils 21 </ b> A and 21 </ b> B are mounted on the stator core 8.
[0042]
In FIG. 14, reference numeral 9 denotes a press plate that prevents the winding coils 21 </ b> A and 21 </ b> B inserted into the tooth portion 10 from falling off. The press plate 9 is locked between the adjacent tooth portions 10.
[0043]
Reference numeral 29 denotes a connection line for electrically connecting adjacent winding coils 21A and 21B. The connection line 29 is an end portion of a flat wire 26-1 serving as a winding end portion of the adjacent winding coil 21A. 26B-1 is connected to the start end 4A-1 of the flat wire 4-1, which is the winding start end of the winding coil 21B.
[0044]
By the way, in this embodiment, as shown in FIG. 15, when the winding coil 21A is inserted into the tooth portion 10 and then the winding coil 21B is integrally inserted into the tooth portion 10, it interferes with the winding coil 21A. The subsequent winding coil 21B cannot be inserted.
[0045]
Therefore, in order to insert the winding coils 21A and 21B in this embodiment, first, the flat wire 26-1 is inserted into the tooth portion 10 and then the flat wire 25-1 is inserted into the tooth portion 10 as shown in FIG. Finally, the rectangular wires 4-1 to 4-4 may be inserted.
[0046]
Although the present embodiment is configured as described above, the shape of the winding coil 21 and the winding coils 21A and 21B is not limited to a rectangular shape, and as shown in FIG. Depending on the shape of the tooth portion or the core, various polygonal shapes, elliptical shapes and the like can be dealt with.
[0047]
The embodiments of the present invention have been described in detail with reference to the drawings. However, the present invention is not limited to the embodiments, and various modifications can be made to the embodiments within the scope of the claims. It can be implemented.
[0048]
【The invention's effect】
Since the winding coil according to the present invention is configured as described above, the winding resistance does not increase at the bent portion as in the conventional winding coil, and the conductor space factor can be increased. it can.
[0049]
In addition, a rectangular wire can be freely formed by selecting winding coils corresponding to teeth portions and cores of various shapes by selecting a rectangular cylindrical conductor block.
[0050]
Furthermore, in the present invention, it is possible to easily obtain a required magnetic flux density by changing the number of rectangular tube conductors or adjusting the incision angle of the coil base material.
[0051]
Furthermore, since a rectangular wire is formed by uniformly cutting a plurality of rectangular tube conductors into a spiral wire and a winding coil is formed using the uniform rectangular wire, it is narrower than a conventional rectangular wire. Further, it has a feature that it is not necessary to consider an increase in winding resistance due to the overlap.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a plurality of rectangular cylindrical conductors forming a coil base material that is a material of a wound coil in one example of the first embodiment of the present invention. The figure which shows the coil base material in one example. [FIG. 3] The perspective view which shows the state in the middle of cutting the coil base material in one example of 1st Embodiment spirally [FIG. 4] 1st Embodiment FIG. 5 is a perspective view showing an entire rectangular wire cut out from a rectangular tube conductor after the helical incision of the coil base material in one example of the embodiment is completed. FIG. 5 is a winding coil in one example of the first embodiment. FIG. 6 is a partial cross-sectional perspective view showing an example in which a winding coil is mounted on a stator core according to another example of the first embodiment. The figure which shows the shape of the continuous winding coil in the other example of 1 embodiment of FIG. The figure which shows the shape of the coil | winding coil shape | molded so that it may insert in the teeth part in the example of FIG. 9. The figure which shows the modification of the shape of the coil | winding coil in 1st Embodiment. FIG. 11 is a perspective view showing a plurality of rectangular tube-shaped conductors forming a coil base material that is a material of a wound coil in the embodiment. FIG. 11 is a view showing a coil base material in the second embodiment. FIG. 13 is a perspective view showing a state in which the coil base material in the embodiment is being cut in a spiral shape. FIG. 13 is a perspective view of the coil base material in the second embodiment, which is cut out from a rectangular tube conductor. FIG. 14 is a partial cross-sectional perspective view showing an example in which the winding coil according to the second embodiment is mounted on a stator core. FIG. 15 is a view taken along an arrow A in FIG. Insert the winding coil in the second embodiment into the teeth Figure [EXPLANATION OF SYMBOLS] showing a modification of the shape of the winding coil in FIG. 17 is a second embodiment for explaining a procedure for
1, 13, 21, 30
Winding coil 2,22
Coil base materials 3-1 to 3-4, 23-1, 24-1
Rectangular cylindrical conductors 4-1 to 4-4, 25-1, 26-1
Flat wire 4A, 25A, 26A
Circuit start ends 4A-1 to 4A-4, 25-A1, 26A-1
Start end 4B, 25B, 26B
Circuit termination portions 4B-1 to 4B-4, 25B-1, 26B-1
Termination parts 5, 6, 7, 11, 27, 28, 29
Connection line 8
Stator core 9
Presser plate 10
Teeth 12 Buffer zone

Claims (4)

A coil base material formed by fitting a plurality of rectangular tube conductors having similar cross-sections in a nested manner without gaps is cut in a spiral shape, and each rectangular tube conductor is formed into a rectangular wire shape. sequentially and incision end of one square tubular conductor formed into a linear shape and incision beginning of another square tube-shaped conductor, one and to the formation of the lead-shaped electrically connected, wherein A winding coil characterized in that the length in the axial direction of each rectangular cylindrical conductor is shortened toward the outer peripheral side . A coil base material formed by fitting a plurality of rectangular tube conductors having similar cross-sections in a nested manner without gaps is cut in a spiral shape, and each rectangular tube conductor is formed into a rectangular wire shape. The incision terminal portion of one rectangular tube conductor formed in a linear shape and the cutting start end portion of another rectangular tube conductor are sequentially electrically connected to form a single wire; A winding coil characterized in that the lengths in the axial direction of the respective rectangular cylindrical conductors are the same. The wound coil according to claim 1 or 2, wherein the incision end portion and the incision start end portion are electrically connected to each other through a stretchable buffer band . The wound coil according to claim 1 or 2, wherein the incision end portion and the incision start end portion are electrically connected via a connection line .

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