JP4482295B2 - Manufacturing method of coil for electric equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a coil for an electric device used for a rotating device such as a motor and a generator, and an electric device such as a transformer.
[0002]
[Prior art]
Conventionally, a coil for an electric device is generally manufactured by an electric device manufacturer using a coil wire manufactured by an electric wire manufacturer. For example, in the case of manufacturing a so-called vertical winding coil in which a rectangular wire is wound with its short cross-section as the coil axis direction as a motor coil, a flat wire coil wire is manufactured by an electric wire manufacturer, and the coil A motor manufacturer manufactures a coil by winding it in a vertical winding.
[0003]
Here, in the method of manufacturing a wire for a rectangular wire by an electric wire manufacturer, for example, as shown in FIG. 10, a round conductor 51 wound around a bobbin 50 is fed and rolled into a rectangular wire 53 by a rolling processing unit 52. After that, the rectangular wire 53 is subjected to predetermined processing in order by the annealing processing unit 54, the conductor surface processing unit 55, and the water washing processing unit 56, and then the resin varnish is applied to the surface of the flat wire 53 by the electrodeposition processing unit 57. An insulating film is formed by electrodeposition, and the electrodeposited insulating film is baked by the first baking portion 58.
[0004]
After that, the overcoat processing unit 60 passes through the film thickness test unit 59, overcoats a resin having lubricity or wear resistance on the insulating coating, and the overcoated resin is baked by the second baking unit 61. After that, the winding unit 63 winds the bobbin 64 in an aligned winding through the dimension measuring unit 62.
[0005]
Further, as shown in FIG. 11, for example, as shown in FIG. 11, a method for manufacturing a longitudinally wound motor coil by a motor manufacturer is supplied in a winding processing unit 71 while sending out a rectangular wire 53 wound around a bobbin 64 in an electric wire manufacturer. The iron core 72 is wound in a vertical winding, and then the entire coil is insulated again.
[0006]
On the other hand, as a method for manufacturing a motor coil without performing the winding process as described above, for example, from an extruded hollow block-shaped material, longitudinal winding is performed by grooving using a cutting tool, wire electric discharge machining, or the like. A method of forming a coil is also known (for example, see Patent Document 1).
[0007]
[Patent Document 1]
JP-A-7-163100 (paragraph 0006, FIGS. 2 to 4)
[0008]
[Problems to be solved by the invention]
However, in the conventional method for manufacturing a motor coil shown in FIG. 10 and FIG. 11, the winding process of winding the round conducting wire 51 around the bobbin 50 and the bobbin 64 at the winding part 63 on the wire manufacturer side. There is a winding process of the flat wire 53. Further, the motor manufacturer has a winding process of the flat wire 53 around the iron core 72, and there are three wire winding processes in total. In addition, on the wire manufacturer side and the motor manufacturer side, tension is applied to the wire by a number of tension adjusting mechanisms.
[0009]
For this reason, in addition to the conductive material, there is a concern that defects may occur due to the action of numerous windings and tensions, or a material that does not break is required, leading to an increase in the cost of the wire.
[0010]
Further, in the wire manufacturing process at the electric wire manufacturer, after an insulating coating is formed on the rolled flat wire 53, an overcoat processing section is used to prevent damage to the insulating coating due to numerous windings such as windings and bobbin winding. In 60, since the resin having lubricity or wear resistance is overcoated on the insulating coating, there is a concern that the cost of the coil wire is increased in combination with the cost increase of the wire.
[0011]
Moreover, even if the resin is overcoated on the insulating film as described above, there are two subsequent wire winding steps and tension is applied by a number of tension adjusting mechanisms. Is likely to occur. Moreover, the vertical coil as the motor coil generally has a very narrow coil interval (pitch) from the viewpoint of increasing the coil occupancy and improving the motor efficiency.
[0012]
For this reason, even if the motor manufacturer winds it up vertically and then insulates the entire coil again, the insulating varnish may not reach the details and the scratches and defects cannot be corrected due to the narrow spacing between the coils. There is a risk of dielectric breakdown when using the motor.
[0013]
Furthermore, in the wire manufacturing process at an electric wire manufacturer, rolling, annealing, surface treatment, water washing, electrodeposition (insulation), baking, film thickness testing, overcoat, baking, dimension measurement, winding, etc. Therefore, it is feared that an enormous facility cost increases, and it becomes difficult to manufacture a flexible wire product. Moreover, since all the lines are stopped by a trouble in one process, there is a concern that quality and productivity are impaired.
[0014]
Furthermore, since the electric wire manufacturer and the motor manufacturer are generally different factories, transportation costs for providing the coil wire manufactured by the electric wire manufacturer to the motor manufacturer are required, and quality control of the coil wire as a product is required. Costs too much.
[0015]
On the other hand, in the method for manufacturing a motor coil disclosed in Patent Document 1 described above, since a hollow block-shaped material is processed to form a vertically wound coil without performing a winding process, There is an advantage that it can be manufactured at low cost.
[0016]
However, in Patent Document 1, there is a description (see paragraph 0011) of fixing an insulating film after processing a block-shaped material into a vertically wound coil shape with respect to the insulating treatment, and no specific method is described. Not.
[0017]
For this reason, in the processed coil shape state, when an insulating coating is formed by electrodeposition of a resin varnish by a known method, the vertical coil in this case also increases the coil occupancy and improves the motor efficiency. Since the coil interval is narrow, the insulating varnish does not reach the details, and the insulating coating cannot be formed uniformly. As a result, quality deteriorates, and there is a concern that dielectric breakdown may occur during use of the motor.
[0018]
Accordingly, an object of the present invention made in view of such a point is that an electrical coil that can easily manufacture a high-quality coil for an electric device having a narrow coil interval and a uniform insulating coating and can be expected to reduce the manufacturing cost. The object is to provide a method of manufacturing a coil for equipment.
[0019]
[Means for Solving the Problems]
The invention of the method for manufacturing a coil for an electric device according to claim 1, which achieves the above object, comprises a conductive member having a rectangular cross section having a coil interval wider than the coil interval of the final product. After the first coiled coil-shaped molded product having the side as the coil axial direction is integrally formed with the fin portion spirally extending along the axial direction on the outer peripheral surface of the column portion by forging the conductive member, A step of punching a portion in the axial direction to manufacture the spiral-shaped fin portion, a step of subjecting the manufactured first molded product to an insulating film forming process to manufacture a second molded product, and the second molded product And manufacturing the final product coil by compressing in the coil axial direction.
[0020]
According to the invention of claim 1, after the first molded product is integrally formed on the outer peripheral surface of the column portion by spiral forging along the axial direction by forging the conductive member, the column portion is axially formed. As the above-mentioned spiral fin part is manufactured into a vertically wound rectangular coil shape, and the insulating film forming process of the first molded product is performed, the rectangular coil can be easily produced with high productivity without performing the winding process. In addition, it is possible to reliably form a uniform insulating film. Therefore, it is possible to easily manufacture a high-quality coil for electric equipment having a narrow coil interval and a uniform insulating film with high productivity, and a significant reduction in manufacturing cost can be expected.
[0021]
The invention for the method for manufacturing a coil for an electric device according to claim 2 is the invention according to claim 1, wherein the insulating coating forming process for manufacturing the second molded article degreases the surface of the conductive member. A step of electrodepositing an insulating material on the surface of the conductive member that has been degreased to form an insulating film, a step of washing the formed insulating film with water, and drying the washed insulating film. And a step of fixing the insulating film that has been dried, and a step of degreasing the insulating film that has been fixed.
[0022]
According to the invention of claim 2, it becomes possible to reliably form a high quality uniform insulating film on the coil surface. Therefore, it is possible to reliably prevent dielectric breakdown when used in electrical equipment.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment and a reference example of a manufacturing method of a coil for an electric device according to the present invention will be described with reference to FIGS.
[0026]
(First Reference Example )
1 to 8 show an embodiment or a reference example of the present invention , FIG. 1 is a diagram showing the whole process, and FIG. 2 is an example of a first molded product by the first molded product manufacturing process shown in FIG. FIG. 3 is a perspective view showing a first molded product manufactured by the manufacturing method of FIG. 2, and FIG. 4 is a schematic diagram for explaining another example of the manufacturing method of the first molded product. FIG. 5 is a perspective view showing the first molded product manufactured in the reference example , FIG. 7 is a side view showing the second molded product, and FIG. 8 is the second molded product. FIG. 9 is a perspective view of a coil for an electric device as a final product.
[0027]
In the present embodiment and the reference example , as shown in FIG. 1, a first molded product manufacturing process, a second molded product manufacturing process, and a final product manufacturing process are sequentially performed to have a longitudinal winding having a desired number of windings. A coil for electrical equipment having a square coil shape is manufactured.
[0028]
For this reason, first, in the first molded product manufacturing process, the short side of the cross-section of the conductive member having a rectangular cross section is set as the coil axis direction without performing the winding process, and the coil interval of the coil 23 for the electric equipment shown in FIG. A vertically wound first coil 21 having a desired number of turns with substantially the same coil spacing as shown in FIG. 6 is manufactured.
[0029]
As a reference manufacturing method for the first molded product 21 having a vertically wound rectangular coil shape by such non-winding processing , for example, manufacturing by processing a conductive hollow rectangular block-shaped material made of copper or aluminum, or There is manufacturing by casting a molten conductive material into a mold.
[0030]
Here, when forming the first molded product 21 by processing the hollow square block-shaped material, any one of cutting tool grooving, wire electric discharge machining, water jet machining, electron beam machining, and laser beam machining is used. Or a combination of these processes.
[0031]
As a manufacturing method of the present embodiment, by forging a conductive member using a die, as shown in FIG. 2, the fin portion 12 that spirally continues along the axial direction is integrated with the outer peripheral surface of the column portion 11. After that, the columnar part 11 can be punched in the axial direction, and a vertically wound first molded product 21 made of a spiral fin part 12 can be manufactured as shown in FIG. In FIGS. 2 and 3, the intervals between the fin portions 12, that is, the coil intervals are widely shown for the sake of clarity.
[0032]
As another manufacturing method, the conductive flat plate is machined by pressing, cutting, or the like, and the start end 16a and the end end are formed by a notch 15 in which a part of the rectangular ring is sequentially displaced as shown in FIGS. After forming a plurality of rectangular annular conductors 16 that are divided into 16b, the rectangular annular conductors 16 are sequentially displaced from each other while the positions of the notches 15 are sequentially shifted. The first end 21a of the vertical winding can also be manufactured by electrically sequentially joining the starting end 16a of the other rectangular annular conductor 16 by the joining means 17 by overlay welding or brazing.
[0033]
That is, in FIG. 4 and FIG. 5, the second rectangular annular conductor 16 is laminated on the first rectangular annular conductor 16 in the lowermost layer, and the end 16b of the first rectangular annular conductor 16 that is in contact with each other overlaps. And the start end 16a of the second square annular conductor 16 are joined by the joining means 17 in the notch 15 of the second square annular conductor 16, and a third corner is formed on the second square annular conductor 16. The ring-shaped annular conductor 16 is laminated, and the end 16b of the second square-shaped annular conductor 16 and the start end 16a of the third rectangular-shaped annular conductor 16 that are in contact with each other overlap each other. 15 is joined by the joining means 17.
[0034]
Thereafter, in the same manner, the (n + 1) th square annular conductor 16 is laminated on the nth square annular conductor 16, and the terminal 16b of the nth square annular conductor 16 and the (n + 1) th square The start end 16a of the annular conductor 16 is joined by the joining means 17 in the notch 15 of the (n + 1) th square annular conductor 16, and the start end 16a of the first square annular conductor 16 and the final square annular conductor 16 are joined. A coil-shaped first molded product 21 having an open end as a terminal 16b is manufactured.
[0035]
4 and 5, the joining means 17 is not limited to build-up welding or brazing, but may be other welding or bonding such as laser welding.
[0036]
In addition, according to the reference example described above, the external shape of the coil axial section as shown in FIG. 6 is a trapezoidal shape, the coil interval is substantially equal to the coil interval L of the final product, and the sectional area of each coil is approximately equal. The first molded product 21 in the shape of a vertically wound square coil having the number of turns
[0037]
Thereafter, in the second molded product manufacturing process, the first molded product 21 is stretched in the axial direction of the coil and the insulating film is formed in a state where the coil interval is widened, as shown in FIG. The second molded product 22 is manufactured. In addition, the coil space | interval at this time is taken as the space | interval which can form an insulating film reliably over the whole conductor surface in the insulating film formation process mentioned later.
[0038]
In the insulating film forming process, for example, as shown in FIG. 8, first, the surface of the stretched first molded article 21 is first degreased (step S1), and then an insulating agent such as an insulating varnish is electrodeposited on the surface (step S2). ) To form an insulating film, and then a washing process (step S3), a drying process (step S4), and a fixing process (step S5) are sequentially performed, and finally a degreasing process (step S6) is performed.
[0039]
In the second molded product manufacturing process, when the second molded product 22 having a coil interval with an insulating coating formed thereon is formed, the second molded product 22 is compressed in the coil axial direction in the final product manufacturing process, and FIG. obtain the desired final product der Ru electrical device coil 23 having a coil spacing as shown in.
[0040]
If the coil 23 for electric equipment manufactured in this way is assembled and used on the stator core of the motor, the coil occupation ratio can be increased, so that the motor efficiency can be improved, and the motor can be reduced in size and weight.
[0041]
As described above, in this reference example , in the first molded product manufacturing process, without performing the winding process, the outer shape of the cross section in the coil axial direction has a trapezoidal shape, and the coil interval is almost the same as the coil interval of the final product. After manufacturing the first molded product 21 of the vertically wound rectangular coil shape made of the conductive member having the first molded product 21 in the second molded product manufacturing process, the first molded product 21 is extended in the coil axis direction to widen the coil interval. In the state, the insulating film forming process is performed to manufacture the second molded product 22, and then, in the final product manufacturing process, the second molded product 22 is compressed in the coil axial direction to manufacture the coil 23 for the electrical product as the final product. Since it did in this way, a winding process becomes unnecessary in all the processes, and each process can be performed independently. Therefore, it is possible to use a desired conductive material without any restrictions on the coil material, and there is no need for an overcoat treatment. For example, a high quality coil for electrical equipment having a narrow coil interval and a uniform insulating film. 23 can be easily manufactured with high productivity, and the manufacturing cost can be greatly reduced.
[0042]
( Embodiment )
In the embodiment of the present invention, as described in the above reference example, the outer periphery of the column portion 11 is shown in FIG. 2 by forging the conductive member using a die in the first molded product manufacturing process . The fin portion 12 that is spirally continuous along the axial direction is integrally formed on the surface, and then the column portion 11 is punched in the axial direction, so that the vertical winding of the spiral fin portion 12 as shown in FIG. The first molded product 21 is manufactured, and the second molded product manufacturing process and the final product manufacturing process are sequentially performed to manufacture the coil for electrical equipment . In the present embodiment, as the first molded product manufactured without performing the winding process in the first molded product manufacturing process, the coil interval wider than the coil interval of the coil for electrical equipment as the final product, for example , the first example of the reference example 2 As with the molded product 22 (see FIG. 7), a first molded product having a wide coil interval capable of reliably forming an insulating coating over the entire conductor surface in the insulating coating forming process described later is manufactured.
[0043]
In the second molded product manufacturing step, the first molded product having a wide coil interval is subjected to the same insulating coating forming process as that of the first embodiment to manufacture a second molded product having an insulating coating on the surface. .
[0044]
Thereafter, as in the reference example , in the final product manufacturing process, the second molded product is compressed in the coil axial direction to obtain a coil for an electric device that is a final product having a desired coil interval.
[0045]
According to this embodiment, in addition to the same effect as the above Reference Example to obtain, especially, since the manufacturing wide coil spacing of the first molded article can be manufactured the first molded product more easily, as a result Productivity can be further improved, and manufacturing costs can be further reduced.
[0045]
The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the invention .
[0046]
【The invention's effect】
As described above, according to the method for manufacturing a coil for an electric device of the present invention, a high-quality coil for an electric device having a narrow coil interval and a uniform insulating film can be easily obtained without performing a winding process. Since it can manufacture, productivity can be improved and manufacturing cost can be reduced significantly.
[0047]
According to another invention, since the coil interval of the first molded product is made wider than the coil interval of the final product, in addition to the effects of the above invention, the first molded product is more easily manufactured. As a result, the productivity can be further improved, and the manufacturing cost can be further reduced.
[Brief description of the drawings]
FIG. 1 is a diagram showing an overall process of a method for manufacturing a coil for an electric device in an embodiment of the present invention.
FIG. 2 is a perspective view for explaining a manufacturing method of an example of a first molded product by a first molded product manufacturing process shown in FIG. 1;
3 is a perspective view showing a first molded product manufactured by the manufacturing method of FIG. 2; FIG.
FIG. 4 is a diagram for explaining a manufacturing method of a reference example of a first molded product in the first molded product manufacturing process shown in FIG. 1;
FIG. 5 is a view taken in the direction of arrow A in FIG.
FIG. 6 is a perspective view showing a first molded product manufactured in a reference example .
FIG. 7 is a side view showing a reference example and a second molded product of the present embodiment .
FIG. 8 is a flowchart showing the sequential steps of the insulating film forming process for manufacturing the second molded product.
FIG. 9 is a perspective view showing a final product.
FIG. 10 is a diagram for explaining a method of manufacturing a coil wire in a wire manufacturer by a conventional method of manufacturing a motor coil.
FIG. 11 is also a diagram for explaining a method of manufacturing a motor coil by a motor manufacturer.
[Explanation of symbols]
21 First molded product 22 Second molded product 23 Coil for electrical equipment (final product)

Claims (2)

A first molded product of a vertically wound coil shape made of a conductive member having a rectangular cross section having a coil interval wider than the coil interval of the final product and having a short cross section of the conductive member as a coil axis direction is formed on the conductive member. After integrally forming a fin portion that spirally continues along the axial direction on the outer peripheral surface of the column portion by forging, a step of punching the column portion in the axial direction to produce the spiral fin portion;
A process for producing a second molded article by subjecting the produced first molded article to an insulating film forming treatment;
And a step of compressing the second molded product in the coil axial direction to manufacture a coil as a final product. The insulating film forming process for manufacturing the second molded article includes a step of degreasing the surface of the conductive member;
Forming an insulating film by electrodeposition of an insulating material on the surface of the conductive member subjected to degreasing;
Washing the formed insulating film with water;
Drying the washed insulating coating; and
Fixing the dried insulating coating; and
The method for producing a coil for an electric device according to claim 1, further comprising a step of degreasing the insulating coating that has been subjected to the fixing treatment.

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