JP4863116B2 - Coil parts, electric motor, fuel pump, and coil winding method - Google Patents

Description

  The present invention relates to a coil part, an electric motor, a fuel pump, and a coil winding method for manufacturing a coil holding structure.

2. Description of the Related Art Conventionally, a coil component that is configured by winding a coil around a bobbin and generating a magnetic flux by energizing the coil has been disclosed (for example, Patent Document 1).
As a structure for maintaining the winding tension of the coil by holding the coil winding end portion or the winding start portion (hereinafter simply referred to as a winding end portion), Patent Document 1 discloses a structure for tangling formed on a bobbin. A structure in which the winding end portion of the coil is wound around the pin and held is adopted. In addition, wrapping the coil in this way is hereinafter referred to as “getting off”.

  Incidentally, when the coil component is applied to the rotor or stator constituting the electric motor, for example, a pair of coil components constituting the U phase of the electric motor, a pair of coil components constituting the V phase, and U In the case where a pair of coil parts constituting a phase are arranged in a ring shape, it is necessary to connect the coils of the same phase that form a pair with a jumper. It is particularly necessary to maintain the winding tension.

JP-A-8-195325

However, in order to hold the winding end portion of the coil, the above-described conventional structure in which the winding end portion is wound on the lashing pin formed on the bobbin requires a space for the lashing pin. Invite
Accordingly, an object of the present invention is to provide a coil component, an electric motor, a fuel pump, and a coil winding method in which the coil winding tension is maintained while achieving downsizing.

According to the first aspect of the present invention, the winding end portion of the coil on the bobbin is wound around the tie portion and is located on the inner side in the radial direction, and is clamped and held between the tie portion and the bobbin. . Thereby, the structure which connects the coil winding end part to the coil itself is easily realizable.
Thus, while eliminating the need for member (tying pin) for tying conventionally required for holding entwined portions end-out winding of the coil, it is possible to maintain the winding tension of the coil. Therefore, the coil winding tension can be maintained while reducing the size of the coil component.

As described in claim 2, the bobbin and coil described in claim 1 are preferably used for an electric motor, and as described in claim 3 , the electric motor described in claim 2 is preferably used for a fuel pump. .

Invention of Claim 4 is a coil winding method, Comprising: The winding procedure which winds a coil around a bobbin, The fastening procedure which ties the coil end part of the coil wound around the bobbin to the coil itself, and holds it, including. In the fastening procedure, the winding end portion is positioned inside the winding portion in the radial direction with respect to the fastening portion, and the wound coil is fastened to the bobbin so that the winding end portion is placed between the fastening portion and the bobbin. Tighten and hold. Thereby, the fastening procedure of tying the winding end part of the coil to the coil itself can be easily realized.
Therefore , it is possible to maintain the winding tension of the coil while eliminating the need for the squeezing member (the squeezing pin), which has been conventionally required to fold and hold the winding start part or the winding end part of the coil. Therefore, the coil winding tension can be maintained while reducing the size of the coil component.

In the fifth aspect of the present invention, the coil is wound around the bobbin up to the binding portion, and then the coil from the binding portion to the winding end portion is wound around the dummy bobbin, and then from the binding portion to the winding end portion. Is extracted from the dummy bobbin, turned over, and fitted into the bobbin, whereby the winding end portion is positioned on the inner side in the radial direction.
Therefore, the fastening procedure of fastening and holding the winding end part between the fastening part and the bobbin can be easily realized.

Hereinafter, an embodiment of a coil component according to the present invention will be described with reference to the drawings.
The coil component according to the present embodiment is applied to a stator of an electric pump that constitutes a vehicle fuel pump. First, the configuration of the fuel pump and the electric pump will be described with reference to FIGS. 2 and 3. 2 is a cross-sectional view of the fuel pump, FIG. 3 (A) is a cross-sectional view showing a single coil component constituting the stator of the electric pump, and FIG. 3 (B) is a top view showing the single stator.

The fuel pump 10 shown in FIG. 2 is an in-tank type turbine pump installed in a fuel tank of a two-wheeled vehicle having a displacement of 150 cc or less, for example.
The fuel pump 10 includes a pump 12 and an electric motor 14 that rotationally drives the pump 12. The housing of the fuel pump 10 includes cylindrical housings 16 and 18, and the housing 16 also serves as a housing for the pump 12 and the electric motor 14.

  The pump 12 is configured such that an impeller 24 is rotatably accommodated in pump cases 20 and 22, and a C-shaped pump passage 202 is formed between the pump cases 20 and 22 and the impeller 24. ing. The fuel sucked from the suction port 200 provided in the pump case 20 is boosted in the pump passage 202 by the rotation of the impeller 24 and is pumped to the electric motor 14 side. The fuel pumped to the electric motor 14 side passes through the fuel passage 204 between the stator 30 and the rotor 60 and is supplied from the discharge port 206 to the engine side.

The electric motor 14 is an inner rotor type so-called brushless motor. The electric motor 14 includes a stator 30, an insulator 40, and a coil 48. As shown in FIG. 3, the stator 30 is composed of six coil cores 32 that are installed separately at equal intervals in the circumferential direction.
Specifically, the stator 30 is configured by annularly arranging a pair of coil cores 32 constituting the U phase of the electric motor 14, a pair of coil cores 32 constituting the V phase, and a pair of coil cores 32 constituting the U phase. The in-phase coil cores 32 that are paired with each other are arranged to face each other. The in-phase coils 48 that form a pair are connected by a jumper (not shown).

The coil core 32 is formed by caulking magnetic steel plates laminated in the axial direction. The coil core 32 includes a tooth 34 extending in the radial direction and an outer core 36 extending on both sides in the circumferential direction on the radially outer side of the tooth 34.
The “coil component” described in the claims is composed of a coil core 32, an insulator 40, and a coil 48. In addition, the “bobbin” described in the claims includes a coil core 32 and an insulator 40.

  The insulator 40 is made of an insulating resin material and has a shape extending in the axial direction (the direction perpendicular to the paper surface of FIG. 3). Further, the insulator 40 is divided into two in the axial direction, and each insulator 40 is inserted from both axial ends of the coil core 32 and attached to the coil core 32. The insulator 40 has an inner flange 42 on the radially inner side and an outer flange 44 on the radially outer side, and forms a winding space between the inner flange 42 and the outer flange 44. The coil 48 is formed by winding a winding in this winding space. The coil 48 is formed by concentrically winding the windings around the insulator 40 for each coil core 32.

  As shown in FIG. 2, the insulating resin material 50 covers the stator 30, the insulator 40, and the coil 48 except for the radially inner peripheral surface and the radially outer peripheral surface of the stator 30. The end cover 52 is integrally molded with the insulating resin material 50 and forms a discharge port 206. The terminal 56 exposed from the end cover 52 and insert-molded is electrically connected to the coil 48.

  The rotor 60 has a shaft 62 and a permanent magnet 64 and is rotatably installed on the inner periphery of the stator 30. Both ends of the shaft 62 are rotatably supported by the bearing 26. The permanent magnet 64 forms eight magnetic pole portions 65 in the rotational direction, and the eight magnetic pole portions 65 are magnetized so that different magnetic poles are alternately formed in the rotational direction on the outer peripheral surface facing the coil core 32. Has been.

Next, a winding procedure for forming the coil 48 will be described.
(1) First, the coil core 32 is formed by caulking magnetic steel plates laminated in the axial direction.
(2) The insulator 40 is fitted and attached to the coil core 32 from both ends of the coil core 32 in the axial direction (perpendicular to the plane of FIG. 4A).
(3) The coil core 32 to which the insulator 40 is attached is placed on the base 122 of the winding device 120 shown in FIG. The mounting surface 124 of the base 122 on which the coil core 32 is mounted is a concave arc surface that matches the convex arc surface of the outer peripheral surface of the outer core 36. Guides 130 and 134 are respectively fixed with bolts or the like on both sides of the base 122 along the axial direction of the coil core 32 and on both ends in the axial direction. The guide surface 132 at the upper end of the guide 130 extends linearly in the axial direction of the coil core 32 and is formed in a smooth convex curved shape with respect to the winding 142 in order to guide the winding 142. Further, the guide surface 136 is formed in a smooth convex curved shape with respect to the winding 142 in order to guide the winding 142.

(4) After the coil core 32 to which the insulator 40 is attached is placed on the base 122, the nozzle 140 that supplies the winding 142 is brought closer to the coil core 32.
(5) Then, as shown in FIGS. 4A and 5, the electric motor 14 rotates while the winding 142 is in contact with the guide surface 132 at the upper end of the guide 130 while tension is applied to the winding 142. The nozzle 140 is swung around an axis extending in the radial direction (vertical direction in FIG. 4).

  An arrow indicated by a symbol P in FIG. 5 indicates a turning locus of the nozzle 140. As indicated by an arrow P, when the nozzle 140 reaches the axial end of the coil core 32, the winding 142 moves from the guide surface 132 of the guide 130 to the guide surface 136 of the guide 134. At this time, in the portion of the insulator 40 where it is difficult to push the winding 142, the rotation of the nozzle 140 is stopped once to improve the alignment state of the winding 142. In this way, the winding 142 is concentrated and wound around the insulator 40 attached to each coil core 32. In addition, illustration of the insulator 40 is abbreviate | omitted in FIG. Moreover, since the shape of the part by which the coil | winding 142 is wound among the insulators 40 is a rectangle, along this shape, the turning locus | trajectory P is also a rectangle.

Next, the details of the procedure for winding the winding 142 around the insulator 40 constituting the bobbin will be described with reference to FIG.
1A is a view as viewed from the arrow A in FIG. 1B, and FIG. 1D is a view as viewed from the arrow D in FIG. 1E. D) Wind in order to the state of (E). In the following description, of the winding 142 as the base material of the coil 48, the winding start portion 142a is the winding start portion 142a, the winding end portion 142b is the winding end portion 142b, and the winding end portion 142b. A portion located closer to the winding start portion 142a is referred to as a anchoring portion 142c.

(5-1): Winding Procedure First, as shown in FIGS. 1A and 1B, the winding 142 is wound around the insulator 40 from the winding start portion 142a to the anchoring portion 142c (winding procedure). . In the example shown in FIG. 1, the winding start portion 142 a is located at a rectangular corner of the insulator 40, and the winding 142 starts to wind from the corner toward the rectangular short side of the insulator 40. The anchoring portion 142c is located on the short side portion of the insulator 40 on the same side as the winding start portion 142a.

(5-2): Fastening procedure 1
Next, as shown in FIG. 1C, the portion from the anchoring portion 142c to the winding end portion 142b of the winding 142 is wound around a dummy bobbin 401 prepared separately from the insulator 40 (fastening procedure 1). Although not shown in FIGS. 4 and 5, the dummy bobbin 401 is provided in the winding device 120. In the example shown in FIG. 1, the winding 142 is wound around the dummy bobbin 401 by one turn. Further, the winding direction of the winding 142 around the insulator 40 is clockwise when viewed from above, whereas the winding direction of the winding 142 around the dummy bobbin 401 is opposite, and is counterclockwise when viewed from above. . The winding end portion 142b is overlaid on the upper side (nozzle 140 side) of the anchoring portion 142c.

  The dummy bobbin 401 has a shape similar to that of the insulator 40, and the winding diameter of the winding 142 around the dummy bobbin 401 is set larger than the winding diameter of the insulator 40. Further, the dummy bobbin 401 is arranged in parallel with the insulator 40. That is, the dummy bobbin 401 is arranged so that the winding axis direction of the dummy bobbin 401 (the direction perpendicular to the paper surface in FIG. 1C) is parallel to the winding axis direction of the insulator 40, and the short side portion of the dummy bobbin 401 is It arrange | positions so that the short side part of the insulator 40 may be opposed.

(5-3): Fastening procedure 2
Next, the portion of the winding 142 wound around the dummy bobbin 401, that is, the portion from the anchoring portion 142c to the winding end portion 142b is extracted from the dummy bobbin 401 and inverted (see the arrow in FIG. 1C). It fits in the insulator 40, and the part wound around the dummy bobbin 401 is put on the part wound around the insulator 40, and it is set to the state of FIG.1 (D) (E) (fastening procedure 2). As a result, the winding end portion 142b is positioned inside the winding portion 142c in the radial direction.

(5-4): Fastening procedure 3
Next, a portion of the winding 142 opposite to the winding start portion 142a with respect to the winding end portion 142b is pulled toward the nozzle 140, and a predetermined tension is applied to the winding 142 (fastening procedure 32). As a specific example, it is possible to apply tension to the winding 142 by a means such as pressing a tension member against the opposite portion or pulling the nozzle 140. As a result, the winding 142 is fastened to the insulator 40 and the winding end portion 142b is fastened and held between the anchoring portion 142c and the other winding portion.

(5-5)
Next, in the winding 142, the opposite side portion of the insulator 40 to the winding start portion 142a and the opposite side portion of the insulator 40 to the winding end portion 142b are cut. As described above, the manufacture of the coil component including the coil 48, the coil core 32, and the insulator 40 formed by winding the winding 142 is completed.
And the fuel pump 10 is manufactured by assembling the coil components manufactured in this way into the housing 16 as shown in FIG.

In the example shown in FIG. 1, in the state shown in FIGS. 1D and 1E in which the winding 142 is wound up, the winding end portion 142b is positioned on the short side portion of the insulator 40 on the same side as the winding start portion 142a. is doing. On the other hand, in the modification shown in FIG. 6, as shown in FIGS. 6D, 6E, and 6F, the winding end portion 142b is located on the short side portion of the insulator 40 opposite to the winding start portion 142a. ing.
Further, the dummy bobbin 401 shown in FIG. 1 is arranged so that the short side portion of the dummy bobbin 401 faces the short side portion of the insulator 40, whereas in the case of the modification shown in FIG. The long side portion of the dummy bobbin 402 is disposed so as to face the long side portion of the insulator 40.

  As described above, according to the present embodiment, the winding end portion 142b of the winding 142 forming the coil 48 is connected to and held by the winding 142 itself. That is, the winding end portion 142b is clamped and held between the anchoring portion 142c and another winding portion. Therefore, it is possible to maintain the winding tension of the coil 48 while eliminating the need for a lashing member that has been conventionally required to fold and hold the winding end portion 142b. Therefore, the winding tension of the coil 48 can be maintained while reducing the size of the coil component.

  Moreover, according to the present embodiment, the dummy bobbins 401 and 402 are arranged such that the winding axis direction is parallel to the winding axis direction of the insulator 40. Therefore, the turning axis that is the center of turning of the nozzle 140 of the winding device 120 is always an axis that extends in the same direction. Therefore, it is unnecessary to move the nozzle 140 so that the swivel axis is inclined in the manufacturing process of the coil component. Therefore, the winding process around the insulator 40 and the winding process around the dummy bobbins 401 and 402 are continuously performed. Can be realized easily. Therefore, automation of the manufacture of coil parts can be easily realized. By the way, the conventional ligation work to the winding end portion 142b of the ligature member has been difficult to automate and has to be manually performed.

(Other embodiments)
In the above embodiment, in the embodiment, the coil component of the present invention is applied to the stator 30 of the electric motor 14. For example, when a motor other than the brushless motor is used for the electric motor 14, the coil component that the rotor has. The coil component of the present invention may be applied to.
Moreover, in the said embodiment, although the coil component of this invention is applied to the electric motor 14, if it is a component provided with the coil which generate | occur | produces magnetic flux by electricity supply, such as a choke coil, the coil component of this invention is applicable. .

In the above embodiment, the winding end portion 142b is tied to and held by the winding 142 itself, but at least one of the winding start portion 142a and the winding end portion 142b is tied to the winding 142 itself. You may make it hold | maintain.
As described above, the present invention is not limited to the above-described embodiment, and can be applied to various embodiments without departing from the gist thereof. For example, the characteristic structures of the above-described embodiments can be arbitrarily set. You may make it combine.

It is a figure which shows the coil winding method which concerns on one Embodiment of this invention, and is a figure explaining the procedure which winds a coil | winding around an insulator. Sectional drawing which shows the electric motor which has the coil components manufactured by the procedure shown in FIG. 1, and the fuel pump by which the electric motor is mounted. (A) is sectional drawing which shows the coil component single-piece | unit manufactured by the procedure shown in FIG. 1, (B) is a top view which shows the stator single-piece | unit comprised by the coil component of (A). (A) is a schematic diagram which shows the coil | winding apparatus for winding a coil | winding to an insulator by the procedure shown in FIG. 1, (B) is a B arrow directional view of (A). The perspective view which shows the nozzle turning locus | trajectory of the winding apparatus shown in FIG. The figure which shows the modification of the coil winding method shown in FIG.

Explanation of symbols

  10: Fuel pump, 12: Pump, 14: Electric motor, 30: Stator, 32: Coil core (coil part, bobbin), 40: Insulator (coil part, bobbin), 48: Coil (coil part), 60: Rotor, 120: Winding device, 142a: Winding start portion (winding start portion), 142b: Winding end portion (winding end portion), 142: Winding, 142c: Fastening portion (fastening portion), 401, 402: Dummy bobbin

Claims (5)

With bobbin,
A coil that is wound in alignment with the bobbin and generates a magnetic flux when energized;
With
The coil has a fastening portion located on the winding start side of the bobbin with respect to the winding end portion of the bobbin, and the winding end portion is wound on the inside of the winding radial direction with respect to the fastening portion. Accordingly , the coil component is clamped and held between the fastening portion and the bobbin . An electric motor having a rotor and a stator,
An electric motor in which at least one of the rotor and the starter includes the bobbin and the coil according to claim 1 . An electric motor according to claim 2 ;
A pump driven by the motor for sucking and boosting fuel;
With fuel pump. A coil winding method of winding a coil that generates magnetic flux by energization around a bobbin,
A winding procedure for winding the coil in alignment with the bobbin;
By wrapping the winding end portion on the inner side in the radial direction with respect to the fastening portion positioned on the winding start side of the bobbin with respect to the winding end portion of the coil on the bobbin, the binding portion and the A fastening procedure for fastening and holding the winding end portion with the bobbin ;
A coil winding method comprising: Preparing a dummy bobbin arranged such that the winding axis direction is parallel to the bobbin winding axis direction;
In the fastening procedure,
Winding the bobbin up to the fastening portion of the coil,
Thereafter, the dummy bobbin is wound around the coil from the tied portion to the winding end portion,
Thereafter, the portion from the fastening portion to the winding end portion is extracted from the dummy bobbin, turned over, and fitted into the bobbin so that the winding end portion is positioned inside the winding portion in the radial direction. The coil winding method according to claim 4 .

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