JP4483658B2 - Field coil manufacturing method and field coil - Google Patents

Description

  The present invention relates to a method for manufacturing a field coil configured by winding a rectangular wire and a field coil.

[Conventional technology]
Conventionally, field windings for automobile starter motors and the like have been used for field windings that are seamlessly formed by edgewise winding in which a flat wire is wound in the axial direction with the width direction facing each other from the beginning to the end. The winding mold used to wind up the magnetic winding is provided with the same number of protruding windings as the number of coils required, and a continuous coil is formed by winding a rectangular wire around the edge one by one around the periphery. Was molded. Patent Document 1 introduces a method of removing a coil from a detachable winding mold and attaching it to a field assembly together with the coil that has been wound up so that it functions as a magnetic pole.

[Problems with conventional technology]
However, this winding method has the following problems. Since winding is performed edgewise while sequentially changing the winding direction clockwise (CW) or counterclockwise (CCW) for each pole, it takes time to complete the winding for four poles, and the productivity is poor. Also, when the coil is rolled up and removed from the removable winding mold and attached to the field assembly, the coil may fall apart even though it is continuous, so a guide is needed to hold it. In addition to the proposed equipment configuration, it is necessary to guide and hold the rectangular wire, and to prevent the wound field coil from interfering with the device, a winding device with an extremely complicated structure is required. Therefore, there is a concern that productivity may deteriorate and reliability of the winding device may decrease.
JP-A-53-55703

  A field coil assembly that can be used for a four-pole DC motor and that has a desired shape and is continuously produced by winding a rectangular wire in an edgewise manner. A method is desired.

  An object of the present invention is to provide a field coil manufacturing method and a field coil having a simple structure and high productivity, which manufacture a field coil having a desired shape which is continuous with edgewise winding of a rectangular wire. is there.

[Means of Claim 1]
In the present invention, a quadrupole DC motor using a rectangular field coil is used, and two continuous coils in which the connecting portion of the two field coils are smoothly bent are used so that they can be mounted on the inner wall of the yoke. of a continuous coil shaped into semi-cylindrical, by junction of coil terminal circumferential coil end of each successive coils, in the manufacturing method of obtaining a cylindrical field coil of 4-electrode DC motor 2 Forming the same field coils of the same formula into a semi-cylindrical shape in opposite directions , combining them in a cylindrical shape facing each other, and joining the coil terminals at the circumferential coil side ends adjacent to each other using a joining member I am characterized.

  According to this method, since the same field coil that can be wound in two poles at the same time is used, only one type of highly productive coil is required, and the coil winding apparatus is simplified.

[Means of claim 2]
2. The method of manufacturing a field coil according to claim 1, wherein when the coil terminals are joined, the coil terminals at the circumferential coil side ends are adjacent to each other and joined. ing.

  According to this method, the length of the joining member can be minimized, and a lightweight coil with a small resistance value can be obtained.

[Means of claim 3]
The field coil manufacturing method according to claim 1, wherein when the coil terminal is joined, the radially inner surface of the coil terminal on the radial yoke side and the radially outer surface of the coil terminal on the radially central side are joined and joined. The thickness of the member is a field coil manufacturing method characterized by a dimension obtained by subtracting the thickness of two rectangular wires from the thickness of the coil.

  According to this method, the field coil terminals can be joined without being shaped in the radial direction, and the winding device is simplified.

[Means of claim 4]
Since it is manufactured by the method for manufacturing a field coil according to any one of claims 1 to 3, a high-performance and inexpensive field coil can be obtained.

  The best mode of the present invention will be described together with Example 1 shown in the drawings.

[Configuration of Example 1]
The manufacturing process of the field coil 3 in Example 1 of this invention is demonstrated sequentially according to FIGS. FIG. 1 is a manufacturing process diagram of a field coil 3 used in the first embodiment. As shown in the drawing, a flat wire 1 cut to a required unfolded length has a free end that is not shown in FIG. It is brought into contact with the core 2 of the apparatus and constitutes a winding start state (FIG. 1 (a)). The winding core 2 forms two pairs whose cross-sectional shapes and dimensions are substantially equal, and is configured to maintain a predetermined initial interval on the left and right in the drawing. The left and right winding cores 2 each have a clamping mechanism (not shown), hold the free end of the flat wire 1 and can rotate (rotate) at the same speed in the left and right (forward and reverse) and simultaneously generate tension. And a moving mechanism (not shown) that is separated from each other.

  Next, since the winding core 2 winds up the free end of the flat wire 1 simultaneously and in the same direction, tension is generated in the winding core 2, and the flat wire 1 is pulled from the center, and the free end is It is wound in close contact with the core 2. FIG. 1B shows a half-turned state.

  When the winding is further advanced and three-quarters of the rotation is performed, a one-turn coil is completed as shown in FIG. It should be noted here that the left and right free ends forming the one-turn coil are wound in an arrangement facing each other with the flat wire 1 interposed therebetween, so that the coil to be formed becomes the field coil 3 in the opposite arrangement.

When the winding is further advanced and rotated once, a winding coil as shown in FIG. 4D is completed, and the left and right winding cores 2 approach each other.
Then, after the predetermined winding rotation, the formed coil in the winding end state is completed as shown in FIG. The connecting portion 32 of the two continuous coils has a straight shape without any deformation or distortion because the tension is always applied.

  And if it removes from the core 2 and the connection part 32 of two continuous coils is bend | folded in a desired shape, the field coil 3 as shown to the front view of the same figure (f) will be completed. In this field coil 3, each free end of the flat wire 1 constitutes a coil terminal 31, and the connecting portion 32 of the left and right coils is sometimes called a jumper wire, and carries current. In addition, since the two continuous coils are wound in the clockwise direction (CW) and the other is wound in the counterclockwise direction (CCW), when the coil terminal 31 is energized, the two coils are generated. The magnetic poles have different orientations.

Then, two types of molded field coils 3 are prepared. One is shaped into an upwardly convex semi-cylindrical shape so that it can be attached to the inner wall of the yoke as shown in FIG. As shown in FIG. 2B, it is shaped into a semi-cylindrical shape convex downward. Shaping may be integrally formed by a press machine or the like, or may be a processing method of rounding sequentially by a roll machine or the like.
These shaped field coils 3 face each other so as to form a cylindrical shape, and one of the pair of coil terminals at the side ends of each field coil 3 has a radially inner surface and the other has a radially outer surface. For example, soldering or fusing, etc., with a joining member 4 having a predetermined thickness (dimension obtained by subtracting the thickness of two rectangular wires from the coil thickness), curvature (dimension approximately equal to the average curvature of the coil), and length. To join firmly.

Then, the cylindrical field coil 3 shown in FIG. 3 can be formed.
FIG. 4 is a front view of the cylindrical field coil 3 (in FIG. 3) formed in the above process as seen from the inside to the outside. The coil terminals 31 at the ends of the adjacent circumferential coils of the field coil 3 are joined together by the joining member 4 to form two continuous flat field coils 3 and then rounded inward. The cylindrical field coil 3 may be configured. Any one can be used as long as it is simple and can be mounted on the yoke without being broken apart when the coil is rolled up.

  FIG. 5 is a perspective view when the cylindrical field coil 3 formed by the above method is mounted on the yoke of a four-pole DC motor. The thickness is uniform in any part, so that the inner diameter and the outer diameter are concentric and can be mounted on the yoke without difficulty.

[Effect of Example 1]
In the present invention, by using a continuous coil in which the connecting portion 32 of the two field coils 3 is smoothly bent, two identical field coils 3 are shaped in a semicylindrical shape in opposite directions, and this is formed into a cylindrical shape. A manufacturing method is adopted in which a field coil of a four-pole DC motor is obtained by combining them together and joining them to the coil terminal 31 using the joining member 4.

  According to this method, it is possible to manufacture a field coil of a 4-pole DC motor only by using the same field coil 3, and only one type of coil and winding device are required. Becomes easier and increases productivity.

  When the coil terminals 31 are joined, since the coil terminals 31 on the circumferential coil side ends are adjacent to each other and joined, the length of the joining member 4 can be minimized, and a lightweight coil with a small resistance value can be obtained. .

  Further, when the coil terminal 31 is joined, the radial inner surface of the coil terminal 31 on the radial yoke side and the radial outer surfaces of the coil terminal 31 on the radial center side are joined, and the thickness of the joining member 4 is: Since the thickness of the field coil 3 is obtained by subtracting the thickness of the two rectangular wires 1 from the thickness of the field coil 3, the coil terminal 31 of the field coil 3 can be joined without being shaped in the radial direction, and the winding device can be easily Become.

[Configuration of Example 2]
The manufacturing process of the field coil 3 in Example 2 of this invention is demonstrated sequentially according to FIGS. The second embodiment is greatly different from the first embodiment in the coil winding method of the flat wire 1. Although the same direction rotation winding of the left and right winding cores 2 does not change, the crossing position of the left and right free ends that determine the arrangement pattern of the field coils 3 is aligned on the same side of the rectangular wire 1, so that FIG. As shown in the plan views of a) and (b), the parallel field coils 3 having the same thickness are formed. In this field coil 3, each free end of the flat wire 1 constitutes a coil terminal 31, and the connecting portion 32 of the left and right coils is sometimes called a jumper wire, and carries current. In addition, since the two continuous coils are wound in the clockwise direction (CW) and the other is wound in the counterclockwise direction (CCW), when the coil terminal 31 is energized, the two coils are generated. The magnetic poles have different orientations.

Then, two sets of molded field coils 3 are prepared. One is shaped into a semi-cylindrical shape that is convex upward so that it can be attached to the inner wall of the yoke, as shown in FIG. Is shaped into a semi-cylindrical shape convex downward as shown in FIG. Shaping may be integrally formed by a press machine or the like, or may be a processing method of rounding sequentially by a roll machine or the like.
These shaped field coils 3 face each other so as to form a cylindrical shape, and one of the pair of coil terminals at the side ends of each field coil 3 has a radially inner surface and the other has a radially outer surface. For example, soldering or fusing, etc., with a joining member 4 having a predetermined thickness (dimension obtained by subtracting the thickness of two rectangular wires from the coil thickness), curvature (dimension approximately equal to the average curvature of the coil), and length. To join firmly.

Then, the cylindrical field coil 3 shown in FIG. 7 can be formed.
FIG. 8 is a front view of the cylindrical field coil 3 (the one shown in FIG. 7) formed in the above process as seen from the inside to the outside. The coil terminals 31 at the ends of the adjacent circumferential coils of the field coil 3 are joined together by the joining member 4 to form two continuous flat field coils 3 and then rounded inward. The cylindrical field coil 3 may be configured. Any one can be used as long as it is simple and can be mounted on the yoke without being broken apart when the coil is rolled up.

[Effect of Example 2]
In the present invention, by using a continuous coil in which the connecting portion 32 of the two field coils 3 is smoothly bent, two identical field coils 3 are shaped in a semicylindrical shape in opposite directions, and this is formed into a cylindrical shape. A manufacturing method is adopted in which the coil terminals 31 are joined together by the joining member 4 to obtain a field coil of a 4-pole DC motor.

  According to this method, the same effects as those of the first embodiment can be obtained, the coil winding device is simplified, the productivity is improved, and the field coil 3 is reduced in weight. Further, since the continuous field coil 3 is formed by two coils arranged in the same thickness, it can be easily shaped into a semi-cylindrical shape, and thus the shaped coil has less distortion, It becomes easy to obtain a cylindrical field coil 3 with high accuracy.

[Configuration of Example 3]
The manufacturing process of the field coil 3 in Example 3 of this invention is demonstrated according to FIG.
The third embodiment differs greatly from the first embodiment in the shape of the coil terminal 31 that is the free end of the coil wound with the flat wire 1. In the first embodiment, each free end is formed by winding the rectangular wire 1 in a coil shape leaving a predetermined length, and the protruding end of the free end is used as a coil terminal 31. Although the continuous field coil 3 which comprised the connecting wire was formed by joining together using the separate joining members 4, in Example 3, the coil terminal 31 of the side which comprises a connecting wire is further connected to the coil surface. Are joined to each other without using a joining member by bending edgewise so that a plane parallel to the surface is formed. The other coil terminal 31 has a shape that protrudes as in the first embodiment.

Two sets of field coils 3 formed in this way are prepared, shaped into semi-cylindrical shapes opposite to each other as in the first embodiment, and the joining surfaces are firmly joined, for example, by soldering or fusing, etc. The field coil 3 can be formed.
FIG. 9 is a perspective view when the cylindrical field coil 3 formed by the above method is attached to the yoke of a four-pole DC motor. The thickness is uniform in any part, so that the inner diameter and the outer diameter are concentric and can be mounted on the yoke without difficulty.

[Effect of Example 3]
In the present invention, by using the continuous field coil 3 in which the connecting portion 32 of the two coils is smoothly bent, the two sets of the same field coil 3 are shaped in a semi-cylindrical shape in opposite directions to each other. A manufacturing method is adopted in which the field coil 3 of the four-pole DC motor is obtained by combining them in a cylindrical shape and joining the coil terminal 31 without a joining member.

  According to this method, the same effects as those of the first embodiment can be obtained, and the manufacturing apparatus can be simplified, the productivity can be improved, and the field coil 3 can be reduced in weight because only one joint is required. .

It is a manufacturing process figure of a field coil, (a) is a coil winding start state, (b) is a half winding state, (c) is a three quarter winding state, (d) is one (E) is an end state of winding, (f) is a front view of a field coil in which a connecting portion is bent (Example 1). It is a shaping process figure of a field coil, (a) is a top view which shows a convex shaping state on the top, (b) is a top view which shows a convex shaping state on the bottom (example 1). It is a top view which shows the assembly | attachment of shaping field coils (Example 1). (Example 1) which is an expansion | deployment front view of a field magnet coil. (Example 1) which is a perspective view of the field coil for 4 pole type DC motors. It is a shaping process figure of a field coil, (a) is a top view which shows a convex shape state in the upper part, and (b) is a top view which shows a convex shape state in the bottom (example 2). (Example 2) which is a top view which shows the assembly | attachment of shaping field coils. (Example 2) which is an expansion | deployment front view of a field magnet coil. (Example 3) which is a perspective view of the field coil for 4 pole type DC motors.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Flat wire 2 Winding core 3 Field coil 31 Coil terminal 32 Connection part (crossover wire)
4 Joining members

Claims (4)

It is a 4-pole DC motor using a flat wire field coil,
Use two sets of continuous coils that smoothly bend the connecting part of the two field coils,
Each continuous coil is shaped into a semi-cylindrical shape so that it can be attached to the inner wall of the yoke,
By junction of coil terminal circumferential coil end of each of said continuous coil,
In the manufacturing how to shape the cylindrical field coil of the 4-electrode DC motor,
Two identical said field coils are shaped into a semi-cylindrical shape in opposite directions ,
Combining in a cylindrical shape facing each other,
A method of manufacturing a field coil, characterized in that the coil terminals at adjacent circumferential coil side ends are joined together using a joining member . In the manufacturing method of the field coil of Claim 1,
A method of manufacturing a field coil, wherein the coil terminals at the circumferential coil side end are adjacent to each other and joined when the coil terminals are joined. In the manufacturing method of the field coil of Claim 1,
When joining the coil terminal, the radially inner surface of the coil terminal on the radial yoke side and the radially outer surface of the coil terminal on the radial center side are joined, and the thickness of the joining member is determined from the thickness of the coil. A method for manufacturing a field coil, characterized in that the thickness is obtained by subtracting the thickness of two flat wires. A field coil manufactured by the method for manufacturing a field coil according to claim 1.

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