JP4763643B2 - Coil and manufacturing method thereof - Google Patents

Description

  The present invention relates to a coil formed by fixing an enameled wire for the purpose of protecting the coil and radiating heat in electromagnetic devices such as a brake, a motor, a generator, and a transformer, and a method for manufacturing the same.

  Conventionally, an enameled wire is fixed and formed for the purpose of protecting the coil from electromagnetic excitation force applied to the coil and environmental load, and facilitating heat dissipation of Joule heat from the coil. As a method for manufacturing such a coil, methods such as self-bonding enameled wire, integral molding, and varnish treatment may be mentioned. Of these, self-bonding enameled wires are used in many devices in that they do not require large equipment such as varnish furnaces and molding machines. A general enameled wire has an insulating layer baked on a conductor, whereas a self-bonding enameled wire has a heat-curable resin self-bonding layer formed on the outer periphery of the insulating layer. .

  In the method of manufacturing a coil using self-bonding enameled wire, when the self-bonding enameled wire is wound around a winding frame, the enameled wires are fixed by heating and pressing the coil and melting the self-bonding layer. . The form of the reel includes a resin part incorporated into a product and a metal jig used only in the manufacturing process. For heating the coil, methods such as hot air blowing in the winding, a heating furnace after coiling, and coil energization are used. In the metal jig winding frame, the coil is removed from the winding frame after the completion of winding, heating and fixing, and the coil formation is completed (see, for example, Patent Document 1).

  When heating and pressurizing the coil with self-bonding enameled wire, the resin material of the self-bonding layer melts and flows out from the point where the self-bonding enameled wires are in contact with each other, and the winding tension is relaxed. There is also an example in which a void is easily formed inside and a reinforcing material in which a self-bonding layer is coated on a strong insulating material is used for reinforcement (for example, see Patent Document 2).

  On the other hand, integral molding is a method in which the coil after winding is fixed by resin molding, and the outer shape of the stator / rotor and brake coil of the motor that takes advantage of the moldability and rigidity of the resin, and heat dissipation by filling the resin. It has been used to improve the performance of the utilized motor (see, for example, Patent Document 3).

JP-A-8-316082 (2nd to 3rd pages, FIGS. 5 and 6) JP-A-8-316023 (page 4-, FIGS. 1-3) Japanese Patent Laid-Open No. 9-322497 (page 3-4, FIG. 3)

  Conventionally, a self-bonding enameled wire used as a method for manufacturing a coil formed by fixing an enameled wire is provided with an insulating layer on the outer periphery of the conductor and further has a self-bonding layer on the outermost periphery. . For this reason, the resin material of the self-bonding layer remains between the adjacent enamel wires, and an extra space corresponding to the thickness of the self-bonding layer is formed as compared with a coil wound with a normal enamel wire. . In devices such as high-efficiency, high-power motors and small brakes that wind coils with high density in a limited space, this extra space reduces the conductor occupation area ratio (coil space factor). There was a problem that it became a bottleneck for high performance of equipment.

  The self-bonding enameled wire has a coil shape that causes the resin material of the self-bonding layer to melt out from the point where the self-bonding enameled wires are in contact with each other when the coil is heated / pressurized, and the winding tension is relaxed. Therefore, there is a problem in that voids are formed in the resin material of the self-bonding layer and the strength is easily lowered.

  Further, in order to avoid this problem of strength reduction, in addition to the self-bonding layer of the self-bonding enameled wire, another bonding material by a complicated process of covering the self-bonding layer with a strong insulator. There is a problem that the material cost increases.

  In addition, since the self-bonding enameled wire does not fill anything in the gaps formed between the enameled wires, heat conduction is poor and heat dissipation compared to a resin-filled coil such as varnish or integral mold. Therefore, there is a problem that it is difficult to apply to high performance motors.

  In high-performance motors, square self-bonding enameled wires may be used instead of round wires to increase the coil space factor. There is a problem that the insulating film tends to be thin, and there is a concern about the possibility of a decrease in insulating performance.

  Similarly, in order to increase the coil space factor, a self-bonding enameled wire in which a round wire is deformed to provide a flat portion parallel to the cross-sectional shape may be used, but the newly formed flat portion and the original There is a problem that the elongation of the insulating film is large at the boundary with the round R portion, and there is a concern that the insulating performance may be deteriorated.

  On the other hand, in the case of the coil by integral molding, the pressure at the time of molding is directly applied to the enameled wire, so the enameled wire wound around the outermost circumference is easy to move, and the enameled wire comes off the reel and the surface of the molding resin on the reel In addition, there is a problem that there is a possibility of touching the iron cores of motors, brakes, etc. and impairing insulation.

  The present invention has been made in order to solve the above-described conventional problems. In the coil space factor, the space corresponding to the thickness of the self-bonding layer is not wasted, and the winding tension is relaxed. A coil that loses strength deterioration due to deformation of the coil shape, and that can improve heat dissipation compared with a self-bonding wire without using a high-cost material, and a manufacturing method thereof. provide.

The coil according to the present invention is
A reel,
An enameled wire wound in a plurality of layers on the winding frame, covering the conductor with an insulating layer , and not covering the surface with a fusion material ;
A continuous thermoplastic resin yarn is arranged in a gap formed by enameled wires that are in contact with each other on the inner and outer layers, and is provided with a molten and solidified thermoplastic resin,
Most of the enamel wires in the inner and outer layers are in direct contact with each other without the thermoplastic resin, and the thermoplastic resin is melted and fixed in a gap between the enamel wires .

A method for manufacturing a coil according to the present invention includes:
A thermoplastic resin yarn that is continuous in the valley between the enamel wires adjacent to each other in the winding direction while winding an enamel wire whose conductor is covered with an insulating layer on the winding frame and whose surface is not covered with a fusion material. Winding the enamel wire in a plurality of layers and winding so that most of the enamel wires in the inner and outer layers are in direct contact with each other ,
After the winding step, the thermoplastic resin yarn is heated and melted so that most of the enamel wires in contact with each other in the inner and outer layers are in direct contact with each other without the thermoplastic resin, and the enamel wires are in the enamel wire. It is made to fix with the said thermoplastic resin fuse | melted in the clearance gap between them.

  According to the coil and the method for manufacturing the coil according to the present invention, the enamel wires are fixed to each other by the molten thermoplastic resin yarn arranged and melted in the gap formed by the adjacent enamel wires in the inner and outer layers, and the above Enamel wires are in contact with each other, and a high-density coil can be obtained without wasting space.

  In addition, the winding tension does not loosen, and it is difficult for the strength to decrease due to the generation of voids. Therefore, it is not necessary to use an insulator coated with a self-bonding layer to ensure strength, and a coil with low material cost can be used Obtainable.

Embodiment 1 FIG.
FIG. 1 is a cross-sectional view illustrating the structure of a coil according to Embodiment 1 of the coil according to the present invention. In FIG. 1 (a), an enameled wire 2 is obtained by coating a conductor 3 such as copper with an insulating layer 4, aligned and wound in an erected state on an insulating winding frame 5, and adjacent enameled wires 2 in contact with each other. A gap is formed between them, and the thermoplastic resin yarn 1 is disposed in this space.

  As shown in FIG. 1 (b), the enamel wire 2 is aligned and wound while guiding the thermoplastic resin yarn 1 to be placed in the vicinity of the valleys outside the adjacent enamel wire 2 of the already wound winding layer. The thermoplastic resin yarn 1 is drawn into the valley and easily positioned, and is wound continuously and synchronously with the winding of the enamel wire 2.

  The thermoplastic resin yarn 1 is made of a single wire of a thermoplastic resin material such as nylon, vinyl chloride, polypropylene, polystyrene, or polyethylene, or a twisted strand of fibrous fine wires.

  Subsequently, when winding by the aligned winding in the stacked state is performed, the enamel wire 2 of the next layer is formed in the valley so as to surround the thermoplastic resin yarn 1 placed in the vicinity of the valley between the outer sides of the adjacent enamel wires 2. The winding is completed as shown in FIG. 1 (a).

  When the enamel wire 2 is energized and heated while being pressed from the outside of the coil after the winding is completed, it is arranged in the gap between the adjacent enamel wire 2 and the enamel wire 2 of the next layer in the same layer. The thermoplastic resin yarn 1 is transferred from each enameled wire 2 and melted, and the enameled wires 2 are fixed to each other.

  FIG. 2 is a cross-sectional view illustrating the structure of another coil according to the first embodiment of the coil according to the present invention. In this example, in addition to the thermoplastic resin yarn 1 in the coil of FIG. 1, another thermoplastic resin yarn 6 is formed between the adjacent enamel wire 2 of the next layer and the enamel wire 2 of the previous layer. It is a point arranged in the gap. In this case, the enamel wire 2 is arranged while being given a tension in a direction toward an obliquely outward valley formed between the lower layer and the upper layer just wound. In this example, the thermoplastic resin yarn 6 can be easily positioned by simply placing it in the obliquely outward valley while applying the tension as described above, and the gaps of the enamel wire 2 can be filled much. Thus, a coil that is more advantageous in terms of heat dissipation can be obtained.

FIG. 3 is a cross-sectional view illustrating the size of the thermoplastic resin yarn in the first embodiment of the coil according to the present invention. FIG. 3 shows a dimensional relationship when a thermoplastic resin thread having a minimum diameter φd is placed in a gap formed in a cross section (diameter φD) of three adjacent enamel wires 2. From FIG. 3, d _min is ,
d ≧ D (1 / COS30 ° -1)
≒ 0.15D
I understand that it is necessary. From this, it can be seen that if an thermoplastic resin yarn having an equivalent circular diameter of at least 0.15 times the outermost diameter φD of the enameled wire is prepared, adjacent enameled wires can be easily fixed.

In addition, the maximum diameter φd _max is, if the gap area is S,
S = (Equilateral triangle-3 fans)
= D × Dsin 60 ° / 2− (πD × D / 4/6 × 3)
= D × D / 4 × (√3-π / 2)
d _max = ∫ (S × 4 / π)
= 0.227D
≒ 0.3D
Is required.

  According to the coil of the first embodiment, the adjacent enamel wires 2 are fixed to each other with the thermoplastic resin thread in the gap formed by the adjacent enamel wires 2 of the upper and lower layers that are aligned and wound in a bowl shape. A high-density coil can be obtained without wasting space.

  In addition, the enamel wire is fixed by melting the thermoplastic resin yarn disposed in the gap between the enamel wire adjacent in the same layer and the enamel wire of the layer adjacent to the outside. The resin material of the self-bonding layer does not remain at the place where the wire contacts, and a high-density coil can be manufactured without wasting space for the thickness of the self-bonding layer.

  Moreover, since the enamel wires 2 adjacent to each other in all the gaps formed by the enamel wires 2 are fixed with the thermoplastic resin yarn, the enamel wires 2 can be fixed more firmly.

  Further, according to the coil manufacturing method of the first embodiment, since the enameled wire 2 does not have a self-bonding layer, when the coil is heated / pressurized, the enameled wire 2 is self-melted from the contact point. The resin material of the adhesion layer does not melt out, the winding tension is not loosened, and the strength is not easily lowered due to the generation of voids. Therefore, it is necessary to use an insulator coated with a self-adhesion layer to ensure the strength. Therefore, a coil with a low material cost can be obtained.

  Further, since the enameled wire 2 has no self-bonding layer, heat generated from the conductor is easily transmitted to the outside, and a thermoplastic resin yarn is formed in a gap formed between the enameled wires 2 aligned and wound in a stacked state. Since it is melted and filled, heat dissipation is improved compared to the gap in the case of a self-bonding enameled wire, and a highly efficient motor with less copper loss can be obtained.

  FIG. 4 is a cross-sectional view illustrating the structure of another coil according to the first embodiment of the coil according to the present invention. In this example, the enameled wire 8 is obtained by baking a flat rectangular conductor 9 with an insulating layer 10 and is wound in an orderly manner so as to stack blocks. When the thermoplastic resin yarn 7 is placed in the valleys outside the adjacent enamel wire 8 of the same layer that has already been wound, it is attracted and easily positioned.

  In general, it is said that the insulating film tends to be thin at the corners of the flat enameled wire, so the thermoplastic resin yarn 7 placed in the valley fixes the corners of the enameled wire 8 after melting. In other words, it is expected to obtain a coil with high density, high strength, good heat dissipation, and easy insulation performance even with a flat enameled wire.

  FIG. 5 is a cross-sectional view illustrating the structure of another coil according to the first embodiment of the coil according to the present invention. In this example, the enameled wire 12 has a conductor 13 that is deformed so that a round conductor is provided with a parallel flat portion before winding. When the thermoplastic resin yarn 11 is placed in the valleys outside the adjacent enamel wire 12 of the same layer that has already been wound, it is attracted and easily positioned.

  The insulating layer 14 is deformed in this way and is given a large elongation at the boundary between the flat portion and the R portion, and the insulating performance is likely to deteriorate. Therefore, after the thermoplastic resin yarn 11 placed in the valley melts, The enameled wire 12 is fixed near the boundary of the R part, and even when the enameled wire is deformed, it is possible to obtain a coil that has high density, high strength, good heat dissipation, and easy insulation. I can expect.

  In the example of the first embodiment, the thermoplastic resin yarn is disposed in the gap between the enamel wires. However, in order to synchronize with the rotation of the winding, it is partially disposed in the gap between the winding frame and the enamel wire. However, the same effect is maintained.

  Further, in the example of the first embodiment, an example of a coil that is aligned and wound is shown. However, when the aligned winding is partially disturbed due to a part manufacturing error or the like, the thermoplastic resin thread is partially enameled. There are places that can be pinched, but if they are partially limited, the coil space factor will not be significantly affected.

Embodiment 2. FIG.
FIG. 6 is a cross-sectional view illustrating the structure of the coil according to the second embodiment of the coil according to the present invention. In the second embodiment, as in the first embodiment, the thermoplastic resin yarn 1 is wound at the time of winding, and after the winding, it is melted by energization heating to fix the enamel wires 2 to each other. In this state, integral molding is performed using a thermosetting resin material such as PPS, epoxy resin, or BMC.

  According to the second embodiment, even if the molding pressure is applied to the enamel wire 2, the enamel wires 2 are fixed to each other, so that they do not peel off or move, and the enamel wire 2 jumps out to the mold surface. It is possible to eliminate the possibility of a decrease in insulation performance such as contact with the iron core.

Embodiment 3 FIG.
FIG. 7 is a front view showing the coil manufacturing apparatus according to the present invention, and FIG. 8 is a cross-sectional view of the coil for explaining the winding operation in the manufacturing apparatus. In the figure, the spindle shaft mechanism 15 rotates the winding frame 5 to wind the enameled wire 2 fed out from the wire bobbin 19 and the thermoplastic resin yarn 1 fed out from the yarn bobbin 20. The nozzle feed shaft mechanism 18 includes an enamel wire nozzle 16 and a thermoplastic resin yarn nozzle 17 and moves the enamel wire 2 in accordance with the rotation of the spindle shaft mechanism 15 by moving it back and forth in a direction parallel to the spindle shaft. It is sent with the pitch accuracy required for aligned winding.

  According to the manufacturing method of the third embodiment, high density and high strength that do not depend on self-bonding wires can be obtained by simply attaching a thermoplastic resin yarn nozzle to an existing spindle type winding machine. -A coil with good heat dissipation can be obtained.

  In FIG. 8, the winding sequence of the enameled wire 2 and the thermoplastic resin yarn 1 to be wound is written in a circular cross section. The numbers of the enameled wire 2 and the thermoplastic resin yarn 1 represent the turns in which the same turn is wound at the same time. As can be seen from FIG. 8, in the first layer, the enamel wire 2 is wound while being sent to the right side in the drawing, and the thermoplastic resin yarn 1 is drawn into the left outer valley so as to follow this. Go. On the other hand, in the second layer, the enameled wire 2 is wound while being sent to the left side in the figure, and the thermoplastic resin yarn 1 is drawn into the right outer valley so as to follow this. Thus, the thermoplastic resin yarn 1 needs to move back and forth relatively with respect to the enameled wire 2 as the layers are folded back. The replacement mechanism 21 for the thermoplastic resin yarn nozzle 17 to change the front-rear position in the direction of the spindle axis 15 with respect to the enameled wire nozzle 16 functions when the layers are folded back as described above. This mechanism 21 includes a method of operating a motor or an air cylinder based on an instruction from a controller, and a method of passively operating a swing at a turnback acceleration while being fixed by a ball plunger. According to this mechanism 21, it is possible to obtain a coil with higher density, higher strength, and better heat dissipation by arranging the thermoplastic resin yarn in the valley of the enameled wire 2 with higher accuracy.

  FIG. 9 is a front view showing another example of Embodiment 3 of the method for manufacturing a coil according to the present invention. In order to wind two types of thermoplastic resin yarns as shown in FIG. 2, the nozzle feed shaft mechanism 18 is for the thermoplastic resin yarns in addition to the enameled wire nozzle 16, the thermoplastic resin yarn nozzle 17 and the yarn bobbin 20. The nozzle 22 and the thread bobbin 23 are provided, and the thermoplastic resin thread 6 can also be wound.

  As described above, the coil of the present invention can be provided by a simple method in which the spindle winding machine comprising the spindle rotating shaft mechanism 15 and the nozzle feed shaft mechanism 18 for winding the enameled wire 2 is used to provide the nozzle for the thermoplastic resin yarn. The manufacturing method of filling the gap with the thermoplastic resin yarn without leakage can be obtained.

Embodiment 4 FIG.
FIG. 10 is a front view showing a coil manufacturing apparatus according to the present invention. The rotating mechanism 32 rotates and drives the flyer head 25 having the enamel wire nozzle 16 and the thermoplastic resin yarn nozzle 17 with respect to the winding frame 5 fixed by the chuck 24, thereby enamel wire 2 and the thermoplastic resin yarn. 1 is wound. At this time, the enamel wire 2 is drawn out from the wire bobbin 19 via the flyer 25 and the rotating shaft, and the thermoplastic resin yarn 1 is drawn out from the yarn bobbin 20 built in the flyer 25 through the nozzle 17. In synchronization with the rotation operation of the rotation mechanism 32, the feed mechanism 26 drives the rotation mechanism 32 back and forth in a direction parallel to the rotation axis, and the enamel wire 2 is wound in an aligned manner. According to this method, the coil of the first embodiment is obtained by a simple method of incorporating a nozzle for a thermoplastic resin yarn and a yarn bobbin on the opposite side to the enamel wire nozzle of the flyer of the existing winding machine. It becomes possible.

  When the coil of the above embodiment is disassembled, by heating, the thermoplastic resin is melted again, the coil is disassembled, the electromagnetic device decomposability is improved, and the recycling cost can be reduced.

  The coil of the present invention can be effectively used for electromagnetic devices such as brakes, motors, generators, and transformers.

It is sectional drawing explaining the structure of the coil in Embodiment 1 of the coil which concerns on this invention. It is sectional drawing explaining the structure of the other coil in Embodiment 1 of the coil which concerns on this invention. It is sectional drawing explaining the magnitude | size of the thermoplastic resin thread | yarn in Embodiment 1 of the coil which concerns on this invention. It is sectional drawing explaining the structure of the other coil in Embodiment 1 of the coil which concerns on this invention. It is sectional drawing explaining the structure of the other coil in Embodiment 1 of the coil which concerns on this invention. It is sectional drawing explaining the structure of the coil in Embodiment 2 of the coil which concerns on this invention. It is a front view which shows the manufacturing apparatus of the coil which concerns on this invention. It is sectional drawing of the coil explaining the return | turnback of winding operation | movement in the manufacturing apparatus of Embodiment 3. FIG. It is a front view which shows the other example in Embodiment 3 of the manufacturing method of the coil which concerns on this invention. It is a front view which shows the manufacturing apparatus of the coil which concerns on this invention.

Explanation of symbols

1,6,7,11 Thermoplastic resin yarn, 2,8,12 Enamelled wire, 3 conductors,
4, 10, 14 Insulating layer, 5 winding frame, 9 flat conductor, 13 deformed conductor,
15 spindle mechanism, 16 enamel wire nozzle,
17, 22 Nozzle for thermoplastic resin yarn, 18 nozzle feed shaft mechanism, 19-wire bobbin,
20, 23 Thread bobbin, 21 Replacement mechanism, 24 Chuck, 25 Flyer head,
26 Feed mechanism, 27 Integrated mold resin material, 32 Rotation mechanism.

Claims (12)

A reel,
An enameled wire wound in a plurality of layers on the winding frame, covering the conductor with an insulating layer , and not covering the surface with a fusion material ;
A continuous thermoplastic resin yarn is arranged in a gap formed by enameled wires that are in contact with each other on the inner and outer layers, and is provided with a molten and solidified thermoplastic resin,
A coil, wherein the enamel wires of the inner and outer layers are in direct contact with each other without the thermoplastic resin, and the thermoplastic resin is melted and fixed in a gap between the enamel wires . 2. The coil according to claim 1, wherein enamel wires in contact with each other in the inner and outer layers are fixed with the thermoplastic resin in all the gaps formed by the enamel wires. The coil according to claim 1, wherein the enameled wire has a circular cross-sectional shape of the conductor, and is wound in a lined manner. 2. The coil according to claim 1, wherein the enameled wire is a rectangular wire having a substantially rectangular cross section. The coil according to claim 1, wherein the enameled wire is provided with a flat portion parallel to the conductor cross-sectional shape by deforming a round wire. The coil according to claim 1, wherein the coil is integrally formed of a thermosetting resin material so as to surround an outermost layer of the enameled wire. A thermoplastic resin yarn that is continuous in the valley between the enamel wires adjacent to each other in the winding direction while winding an enamel wire whose conductor is covered with an insulating layer on the winding frame and whose surface is not covered with a fusion material. Winding the enamel wire in a plurality of layers , and winding so that the inner and outer layer enamel wires are in direct contact with each other ,
After the winding step, the thermoplastic resin yarn is heated and melted so that the enamel wires in contact with each other in the inner and outer layers are directly in contact with each other without the thermoplastic resin, and are melted in a gap between the enamel wires. A coil manufacturing method comprising fixing with a thermoplastic resin. The enameled wire and the thermoplastic resin yarn are the enameled wire nozzle that rotates the winding frame and supplies the enameled wire in the direction of the rotation axis of the winding frame, and the thermoplastic resin yarn nozzle that supplies the thermoplastic resin yarn. The coil manufacturing method according to claim 7, wherein the coil is wound by a winding machine having a mechanism for moving back and forth. The winding machine is characterized in that, during winding, the thermoplastic resin yarn nozzle is wound with a mechanism for switching the front and rear positions in the rotation axis direction with respect to the enameled wire nozzle when the layers are folded back. The method for manufacturing a coil according to claim 8. 8. The coil according to claim 7, wherein the enamel wire is wound by a winding machine provided with the nozzle for enamel wire and the two nozzles for thermoplastic resin yarn, with the winding frame rotating. Manufacturing method. The enameled wire and the thermoplastic resin yarn are the enameled wire nozzle that fixes the winding frame and supplies the enameled wire in the central axis direction of the winding frame, and the thermoplastic resin yarn nozzle that supplies the thermoplastic resin yarn. The coil manufacturing method according to claim 7, wherein the coil is wound by a winding machine provided with a mechanism for rotating the coil around the central axis. 8. The method of manufacturing a coil according to claim 7, wherein the thermoplastic resin yarn has an equivalent circular diameter of a cross-sectional area of not less than 0.15 times and not more than 0.3 times the outer diameter of the enamel wire.

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