JP4709045B2 - Armature manufacturing method - Google Patents

Description

  The present invention relates to an armature used for a rotating electric machine, a linear motor, or the like.

  Conventionally, the insulator in the winding portion of the armature is substantially equal to the wire diameter of the magnet wire in the portion where the magnet wire is wound in order to improve the alignment of the wound magnet wire (alignment winding). A groove having a shape is formed.

  In order to form a groove matching the wire diameter of the magnet wire in the insulator, a method of manufacturing by injection molding using a mold, or an insulator in which no groove is formed as described in Patent Document 1 A method of forming grooves according to the wire diameter by machining is employed.

Japanese Patent Laid-Open No. 9-223639 (page 4-6, FIG. 5)

  When forming an armature insulator to form a winding groove, a method of mass production by injection molding using a mold has been generally used because of cost advantage. However, since it is necessary to change the pitch of the groove according to the wire diameter of the magnet wire, it is necessary to prepare a mold according to the pitch of the groove. There was a problem that was difficult.

  In addition, when the groove processing according to the wire diameter is performed by machining, it can be shaped relatively easily if the shape of the insulator is cylindrical, but in the case of other shapes, for example, the stator of a rotating electrical machine As described above, when a rectangular insulator is used, there is a problem that processing may become difficult.

  The present invention is intended to solve the above-described problems, and can be used for high-mix low-volume production, and an electric machine equipped with a groove forming method that can also handle various shapes of insulators. It aims at providing the manufacturing method of a child.

In the first armature manufacturing method according to the present invention, a magnet wire is fixed to each of the magnetic pole teeth of the iron core having a plurality of magnetic pole teeth protruding from the yoke portion via an electrically insulating insulator made of a thermoplastic resin. In the manufacturing method of the armature in which the coil is formed by the aligned winding wound at the pitch,
Forming a heating element in which linear portions having a wire diameter equal to or less than the wire diameter of the magnet wire are arranged in parallel at a constant pitch of the magnet wire when the magnet wire is aligned and wound;
Heating the heating element to a temperature equal to or higher than the softening temperature of the insulator;
The linear part of the heating element is pressed against part or all of the coil forming part of the insulator to form a groove,
The coil is formed by winding the magnet wire along the groove.

According to the second armature manufacturing method of the present invention, a magnet wire is fixed to each of the magnetic pole teeth of the iron core having a plurality of magnetic pole teeth protruding from the yoke portion via an electrically insulating insulator made of a thermoplastic resin. In the manufacturing method of the armature in which the coil is formed by the aligned winding wound at the pitch,
After heating the magnet wire to a temperature equal to or higher than the softening temperature of the insulator and winding the magnet wire one layer,
A magnet is provided to each of the magnetic pole teeth of the iron core having a plurality of magnetic pole teeth projecting from a yoke portion that is wound without heating the second and subsequent layers to form the coil via an electrically insulating insulator made of a thermoplastic resin. In the method of manufacturing an armature that forms a coil by aligned winding in which wires are wound at a constant pitch,
After heating the magnet wire to a temperature equal to or higher than the softening temperature of the insulator and winding the magnet wire one layer,
The second and subsequent layers are wound without heating to form the coil.

In the third armature manufacturing method according to the present invention, a magnet wire is fixed to each of the magnetic pole teeth of the iron core having a plurality of magnetic pole teeth protruding from the yoke portion via an electrically insulating insulator made of a thermoplastic resin. In the manufacturing method of the armature in which the coil is formed by the aligned winding wound at the pitch,
The insulator is heated to a softening temperature and the magnet wire is wound to form the coil.

  According to the first, second and third armature manufacturing methods according to the present invention, there is no need to manufacture a mold for forming a groove corresponding to the wire diameter of the magnet wire, and the shape of the insulator is cylindrical. Since the grooves can be easily formed even if they are not in the shape, machining is not necessary, and machining of various types of insulators can be performed inexpensively and easily.

  Further, according to the second armature manufacturing method of the present invention, since the groove corresponding to the change in the wire diameter of the magnet wire due to the change in the tension with respect to the magnet wire applied in the winding is formed directly in the insulator, Reliability in winding alignment is improved. Moreover, since a groove is formed in the insulator by heating the magnet wire to be wound, no heating element is required.

  In addition, according to the third armature manufacturing method of the present invention, it is only necessary to heat only the insulator, so that the heating range can be reduced.

Embodiment 1 FIG.
FIG. 1 is a perspective view showing an armature according to a first embodiment of the present invention, wherein (a) and (c) show an insulator fitted into a magnetic pole tooth portion of a stator core in a rotating electric machine, and (b). Indicates the magnetic teeth of the stator core. In the stator core 4 of FIG. 1B, one salient pole of the stator is enlarged. Note that windings are omitted.

  As shown in FIG. 1, a stator 1 of a rotating electric machine includes a stator core 4 having a yoke portion 2 having a predetermined thickness and a magnetic teeth portion 3 protruding from the yoke portion 2, and a magnetic teeth portion of the stator core 4. And an insulator 5 made of a pair of thermoplastic resins fitted from above and below so as to cover 3. As the insulator 5, for example, LPC (Liquid Crystal Polymer) can be used, and in this example, an example using LPC is shown. The insulator 5 is formed of a winding portion 6 and a flange portion 7, and a plurality of grooves 8 are provided on a part of the outer peripheral surface of the winding portion 6. The groove 8 provided in the insulator 5 has an arc shape whose cross section is the same as or smaller than the wire diameter of the magnet wire, and in FIG. From one end to the other end of the part, the pitch is set in parallel with the flange 7 surface at a pitch when the magnet wire is wound in an aligned manner or at a predetermined angle. For example, in FIG. 1, nine grooves 8 are provided at the same depth in the winding portion. The depth of the groove 8 is preferably not more than the radius of the wire diameter of the magnet wire.

  FIG. 2 is a plan view (a), (b) and sectional views (c), (d), (e) showing the first embodiment of the armature manufacturing method according to the present invention. 1. AA sectional drawing of FIG. 1, (d), (e) is BB sectional drawing of (c). As shown in FIG. 2 (a), when a magnet wire is wound by winding a predetermined number of heating wires (nichrome wire) 9 having a diameter equal to or smaller than the wire diameter of the magnet wire. 2 is used to heat the heat generating element 10 to a temperature at which the insulator 5 can be melted by flowing a current through the heat generating element 10, and is heated to 250 ° C. in this example. As shown by the arrows in a) and FIG. 2 (d), the heating element 10 is pressed against the corner of the winding part 6 of the insulator 5 and the corner where the heating element 10 is pressed is set to the wire diameter of the heating element. By melting, the groove 8 is formed as shown in FIGS. 2 (b), 2 (c) and 2 (e). As shown in FIG. 2B, the grooves 8 are formed at a pitch p when the magnet wires are wound in an aligned manner.

FIG. 3 is a plan view showing another example of groove formation in the first embodiment.
In FIG. 2, the grooves 8 are formed at the corners of the winding portion 6 of the insulator 5. However, as shown in FIG. 3, the grooves 8 may be formed at the upper plane portion of the winding portion 6 of the insulator 5. .

  In addition, by coating the surface of the heating wire 9 with a fluororesin resin or the like, the molten resin of the insulator 5 can be prevented from adhering to the heating wire 9.

  Conventionally, it has been necessary to prepare dies having different groove dimensions according to the wire diameter and the number of layers of the magnet wire. According to the first embodiment, the wire diameter of the magnet wire wound around the insulator 5 is used. Accordingly, the heating element 10 is formed by arranging the heating wires 9 or the bar heaters 12 having a diameter equal to or smaller than the diameter of the magnet wire in parallel in accordance with the pitch of the magnet wire when the magnet wire is aligned and wound. 10 can be used to form the groove 8 in the winding portion 6 of the insulator 5, eliminating the need to have a plurality of molds as in the prior art. Using the heating element 10 with the wire diameter and pitch of the heat wire 9 changed, it can be easily and easily handled.

  Moreover, since it can process in a short time compared with the method of forming the groove | channel 8 by machining, cost can be reduced and productivity can be improved.

  In the first embodiment, an example in which the heating element 10 in which the heating wire 9 is bent in a W shape is used as a means for forming the groove 8 is shown. However, as shown in FIG. The heating element 11 formed in a shape may be used. In this case, the heating element 9 can be easily manufactured simply by winding the heating wire 9 around a round bar or a square bar.

  Moreover, the cross-sectional shape of the heating wire 9 may be a quadrangle when the cross-sectional shape of the magnet wire is a quadrangle in accordance with the cross-sectional shape of the magnet wire.

  As shown in FIG. 5, instead of the heating wire 9, the bar heaters 12 may be arranged in parallel at a predetermined pitch, and the heating elements 13 may be fixed to the bar heaters 12 arranged in parallel. In this case, since the bar heater 12 has higher rigidity than the heating wire 9, it is possible to prevent the heating element 13 from being deformed when pressed against the resin.

  Further, when the groove 8 is formed by pressing the heating elements 10, 11 and 13 against the insulator 5 while being heated until the insulator 5 is melted, the insulator 5 is removed when the heating elements 10, 11 and 13 are separated from the insulator 5. May be stretched on the heating elements 10, 11, and 13 to form burrs, but the heating elements 10, 11, and 13 that are heated until the resin of the insulator 5 is melted are formed in the insulator 5. After the groove 8 is formed by pressing, the heating elements 10, 11, and 13 are forcibly cooled by air and lowered to the softening temperature of the resin (about 200 ° C. in this example), and the heat is generated after the shape of the groove 8 is fixed. The bodies 10, 11, and 13 may be pulled apart. In this case, after the groove 8 is formed in the insulator 5, the heating element 10, 11, 13 is separated from the insulator 5 after the temperature at which the resin is softened, so that the groove 8 is formed satisfactorily without forming burrs. be able to. For this reason, the shape accuracy of the groove can be kept good, the magnetic wire can be prevented from being damaged by burrs, and the quality can be improved.

  Moreover, the temperature of the heat generating elements 10, 11 and 13 may be a temperature (about 200 ° C.) at which the resin of the thermoplastic insulator 5 is softened. After the heating elements 10, 11, and 13 are heated until the resin of the thermoplastic insulator 5 is melted, the heating elements 10, 11, and 13 are pressed against the insulator 5 to form the grooves 8, and then the heating elements 10, 11 are formed. , 13 is air-cooled, and when the shape of the groove 8 is fixed and the heating elements 10, 11, 13 are separated, the heating elements 10, 11, 13 need to be forcibly cooled, so the grooves 8 are formed. Although cooling time is required for this, the tact may be lengthened. However, the heating elements 10, 11, 13 are heated in a state where the heating elements 10, 11, 13 are heated to a temperature at which the resin of the thermoplastic insulator 5 is softened. By forming the groove 8 by pressurizing the insulator 5, it is possible to prevent burrs from being formed in the groove 8 portion and to improve the accuracy of the formed groove 8, and to generate the heating elements 10, 11, 13. Forcibly cool Since there is no necessity shortened molding time of the groove 8, it is possible to enhance the productivity.

  Further, if the shape of the bar heater 12 is changed in accordance with the cross-sectional shape of the magnet wire, the groove 8 having a desired shape such as an arc shape or a square shape can be easily formed.

Embodiment 2. FIG.
In the first embodiment, the heating wire 9 or the bar heater 12 of the heating elements 10, 11, 13 is pressed against the insulator 5 to form the groove 8. When the heating wire 9 or the bar heater 12 of the heating elements 10, 11, 13 is pressed against the insulator 5 as it is, the heating wire 9 and the bar heater 12 may be deformed when the insulator 5 is melted or separated after melting. Further, when the heat capacity of the heating elements 10, 11, and 13 is increased, the cooling capacity is limited even if forced air cooling is performed.

  6, 7 and 8 are a plan view and a cross-sectional view showing a second embodiment of the armature manufacturing method according to the present invention, and FIG. 6 and FIG. 7 (a) are plan views, FIG. 6 and FIG. (B) of FIG. 8 is a sectional view, FIG. 8 (a) is a front view, FIG. 8 (b) is a side view, and FIG. 8 (c) is a sectional view.

  In the second embodiment, as shown in FIG. 6, the arc-shaped groove 15 having the same diameter as the heating wire 9 is formed in the groove 15 of the metal plate 14 formed at the pitch when the magnet wires are wound in an aligned manner. The heating wire 9 is fixed to the groove 15 by arranging a linear portion of the heating wire 9 bent in a predetermined shape in a W shape.

  In addition, as shown in FIG. 7, the grooves 17 are formed in a cylindrical or square rod-shaped member 18 in which the grooves 17 are spirally or concentrically formed with respect to the axis at the pitch when the magnet wires are aligned and wound. The linear portion of the heat wire 9 may be disposed and fixed.

  Further, as shown in FIG. 8, grooves 19 having a predetermined depth are formed at a pitch when the magnet wires are aligned and wound on the L-shaped metal plate 20, and rods are formed on the grooves 19 of the L-shaped metal plate 20. The heater 12 may be disposed and fixed.

  According to the second embodiment, when the heating wire 9 or the bar heater 12 is pressed against the insulator 5, the heating wire 9 or the bar heater 12 is held by the grooves 15, 17 or 19, so that it does not deform.

  Further, since the heating wire 9 is disposed on the metal plate 14 or the rod-shaped member 18 or the bar heater 12 is disposed on the L-shaped metal plate 20, the heating wire 9 or the rod heater 12 is forcibly cooled. Even in the case, the water cooling structure can be applied, so that the cooling capacity can be improved.

  Further, by arranging the heating wire 9 so that a part of the heating wire 9 protrudes from the metal plate 14 by a certain amount, the groove 8 having an appropriate and uniform depth can be formed.

  Further, as the columnar or square rod-shaped member 18, a metal material or a material having high heat conductivity and good heat dissipation is formed, and a spiral or concentric groove 17 is formed on this material, and the coil 17 is simply wound around the groove 17. Thus, a heating element with good heat dissipation can be easily manufactured.

Embodiment 3 FIG.
In the second embodiment, the heating wire 9 and the bar heater 12 are installed on a metal plate corresponding to each shape to constitute a heating element, and the heating wire and the bar heater for forming the groove 8 in the insulator 5 are used. Although the prevention of deformation and the improvement of the cooling performance of the heating element are intended, since the groove 8 is formed by pressing the heating wire 9 and the bar heater 12 directly on the insulator 5, the dimensions of the groove are the heating wire 9 and the bar heater 12. The shape of the groove 8 is not flexible.

  Further, the dimensional accuracy of the groove 8 may be lowered due to deterioration of the heating wire 9 or the bar heater 12 due to repeated use.

  9 and 10 are plan views (a) and (b) and sectional views (c), (d) and (e) showing a third embodiment of the armature manufacturing method according to the present invention. In the third embodiment, as shown in FIG. 9, a material having a high thermal conductivity, for example, copper, arranged in parallel at a pitch when magnet wires are aligned and wound, has a circular cross section and a linear shape. Protruding portions 21 were provided to constitute a heating element 22 in which a heater was built in by pasting or embedding.

  In FIG. 10, an aluminum alloy having good resonance characteristics or a titanium alloy having high strength is provided with convex portions 22 each having an arcuate cross section and a linear shape arranged in parallel at a pitch when magnet wires are aligned and wound. A horn 23 is formed, the horn 23 is connected to an ultrasonic oscillator (not shown), and the groove 8 is formed using ultrasonic vibration.

  According to the third embodiment, since the arc-shaped convex portion 21 can be freely formed with high accuracy by machining, the groove 8 with high accuracy can be formed.

  Moreover, it can respond to any formation method of the method of forming the groove | channel 8 in a corner | angular part demonstrated in Embodiment 1, and the method of forming the groove | channel 8 in a plane.

  Further, since the deterioration due to repeated use is only in the heater, it can be used semipermanently by replacing the heater.

  Further, by forming the groove 8 using ultrasonic vibration, the groove is formed by pressurization of the horn 23 and friction caused by ultrasonic vibration, so that it is odorless at the time of forming, and standby power other than at the time of ultrasonic oscillation. Therefore, the work environment is good and energy is saved.

Embodiment 4 FIG.
In the first to third embodiments, the groove 8 is formed in the insulator 5 using a heating element or ultrasonic vibration. In the method using the heating element or the ultrasonic vibration, it is necessary to separate the step of forming the groove 8 in the insulator 5 and the step of winding.

  FIG. 11 is a plan view showing Embodiment 4 of the armature manufacturing method according to the present invention. As shown in FIG. 11A, in the fourth embodiment, as shown in FIG. 11B, the magnet wire is wound around the insulator 5 by heating only the first layer of the magnet wire. The groove 8 of the magnet wire is transferred to the insulator 5 and the position of the magnet wire is determined. Thereafter, winding is performed without heating the second and subsequent layers.

  According to the fourth embodiment, since the groove 8 corresponding to the change in the wire diameter of the magnet wire due to the change in the tension in the winding is formed directly in the insulator 5, the reliability in the alignment of the winding is improved. .

  Further, since the groove 8 is formed in the insulator 5 by heating the magnet wire to be wound, it is not necessary to prepare a heating element or a horn according to the model (wire diameter).

  Further, in the fourth embodiment, instead of heating the magnet wire in advance and winding it around the insulator 5, the insulator 5 is heated and softened, and the magnet wire is wound around the softened insulator 5 in the same manner. The effect is obtained. In this case, it is not necessary to heat the magnet wire for the first layer, and only the insulator 5 needs to be heated, so that the heating range is small.

  In the first to fourth embodiments, the present invention has been described by taking a rotating electric machine as an example. However, the present invention can also be applied to an insulator of an armature of a linear motor.

  The present invention can be effectively used for the winding of an armature used in a rotating electric machine, a linear motor, or the like.

It is a perspective view which shows Embodiment 1 of the armature which concerns on this invention. It is the top view and sectional drawing which show Embodiment 1 of the manufacturing method of the armature which concerns on this invention. FIG. 10 is a plan view showing another example of groove formation in the first embodiment. FIG. 6 is a plan view and a cross-sectional view showing another manufacturing method in the first embodiment. FIG. 6 is a plan view (a), (b) and sectional views (c), (d), (e) showing other processes in the first embodiment. It is the top view and sectional drawing which show Embodiment 2 of the manufacturing method of the armature which concerns on this invention. It is the top view and sectional drawing which show Embodiment 2 of the manufacturing method of the armature which concerns on this invention. It is the top view and sectional drawing which show Embodiment 2 of the manufacturing method of the armature which concerns on this invention. It is the top view and sectional drawing which show Embodiment 3 of the manufacturing method of the armature which concerns on this invention. It is the top view and sectional drawing which show Embodiment 3 of the manufacturing method of the armature which concerns on this invention. It is a top view which shows Embodiment 4 of the manufacturing method of the armature which concerns on this invention.

Explanation of symbols

1 Stator, 2 Yoke part, 3 Magnetic teeth part, 4 Stator core,
5 Insulator, 6 Winding part, 7 Flange part, 8 Groove, 9 Heating wire,
10, 11, 13, 21 heating element, 12 bar heater, 14 metal plate,
15, 17, 19 groove, 18 cylindrical iron core, 20 L-shaped metal plate, 22 convex part,
23 Horn, 24 Magnet wire.

Claims (7)

An armature that forms a coil on each of the magnetic pole teeth of the iron core having a plurality of magnetic pole teeth protruding from the yoke portion by aligned winding in which a magnet wire is wound at a constant pitch via an electrically insulating insulator made of a thermoplastic resin. In the manufacturing method of
Forming a heating element in which linear portions having a wire diameter equal to or less than the wire diameter of the magnet wire are arranged in parallel at a constant pitch of the magnet wire when the magnet wire is aligned and wound;
Heating the heating element to a temperature equal to or higher than the softening temperature of the insulator;
The linear part of the heating element is pressed against part or all of the coil forming part of the insulator to form a groove,
A method of manufacturing an armature, wherein the coil is formed by winding the magnet wire along the groove. 2. The method of manufacturing an armature according to claim 1, wherein the heating element is configured by forming the linear portion by arranging heating wires or bar heaters in parallel. 3. The armature manufacturing method according to claim 2, wherein the heating wire or the bar heater is coated with a fluororesin resin. The heating element is embedded and fixed in the groove of a plate-like member or rod-like member in which grooves having the cross-sectional shape of the linear part are formed in parallel so that a part of the linear part protrudes from the groove. The armature manufacturing method according to claim 1, wherein the armature is manufactured. The heating element is composed of a groove forming member in which the linear portion made of a linear protrusion is formed on a material having good thermal conductivity, and a heating element incorporated in the groove forming member. The method for manufacturing an armature according to claim 1. The heating element is constituted by a groove forming member in which the linear portion made of a linear convex portion is formed on a material having good thermal conductivity, and an ultrasonic transmitter for ultrasonically vibrating the groove forming member. The method of manufacturing an armature according to claim 1. 2. The armature manufacturing method according to claim 1, wherein the heating element is configured by winding a heating wire around a round bar or a square bar.

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