JP5044127B2 - Method for manufacturing aggregate conductor - Google Patents

Description

  The present invention relates to a method for manufacturing an aggregate conductor in which a plurality of conductor wires are integrated.

  A collective conductor in which a plurality of conductor wires are bundled and configured integrally is proposed.

  In Patent Document 1, a plurality of enameled wires having a circular cross section are arranged and twisted so as to be arranged in two horizontal rows, and the entire cross section is formed into a rectangular flat twisted wire. Is disclosed. And according to this, it is described that the space factor in a coil | winding can be improved.

  Patent Document 2 discloses a self-bonding assembly line in which a self-bonding layer is provided on the outside of an assembly line in which a plurality of insulating wires are bundled, and an insulating layer and a self-bonding layer are sequentially formed on a conductor. A plurality of fusion-insulated wires are bonded in parallel by bonding the self-bonding layers, and a thermoplastic self-bonding layer is formed on the outer periphery of the bundled assembly line. And according to this, when the outer self-bonding layer is formed, it is difficult for the insulation element wire to be scattered, and even when winding in a complicated shape such as a deflection coil, the insulation element wire does not protrude or break. It is described that the coil space factor can be ensured with a large conductor cross-sectional area.

Patent Document 3 discloses a self-bonding dislocation electric wire in which a plurality of self-bonding rectangular enamel wires are assembled, dislocated, and twisted and wound around an outer periphery of a twisted wire with an insulating tape spirally wound. What is disclosed is a self-lubricating / self-bonding flat enameled wire. And according to this, during manufacturing work of the dislocation wire and coil winding work, the strands of each other exhibit excellent mutual slipperiness, and the strands can be firmly heat-sealed when the coils are heat-sealed. Are listed.
Japanese Patent Laid-Open No. 2-242531 JP-A-9-161547 Japanese Patent Laid-Open No. 11-203948

  By the way, an induction motor (induction motor), a brushed DC motor, a brushless DC motor, and the like are often used for driving an electric vehicle.

  For example, the induction motor includes a stator core formed in a cylindrical shape, a coil attached to the stator core, and a rotor rotatably arranged with a certain gap on an inner peripheral wall of the stator core, and induction generated in the coil The rotor is rotated by a magnetic field to obtain a driving force.

  The stator core includes a plurality of concave portions (slots) and convex portions that are alternately formed in the circumferential direction on the inner peripheral wall or the outer peripheral wall. In each slot, a conductor wire such as an enamel wire constituting a coil is disposed.

  FIG. 14 is a cross-sectional view in which a plurality of conductor wires 103 having a circular transverse cross section are arranged in the slots 130b between the protruding strip portions 130a. Here, the conductor wire 103 includes a conductor wire 101 through which a current flows and a covering layer 102 covering the periphery thereof. In FIG. 14, since the conductor wire 103 having a circular cross section is disposed in the slot 130b, a dead space is formed between the conductor wires 103, and the filling rate of the conductor wire 103 inside the slot 130b is as follows. It is low.

  In recent years, motors for electric vehicles such as hybrid vehicles are often driven by high-frequency alternating current generated by an inverter. For example, in the case of FIG. 14, the current flowing through the conductor wire 103 is caused by the skin effect. The AC resistance increases due to concentration near the surface of the conductor wire 101.

  Therefore, in order to increase the filling factor of the conductor wire 103 inside the slot 130b, that is, the area of the conductor occupying a predetermined area (conductor space factor) and reduce the AC resistance due to the skin effect and eddy current, As the conductor to be inserted into the conductor, for example, an aggregate conductor as described in Patent Documents 1 to 3 can be used.

  In the collective conductor as described above, since the plurality of conductor wires are bundled, the skin current is divided and the eddy current is canceled between adjacent conductor wires, so that the AC resistance can be lowered. However, in an aggregate conductor composed of a plurality of conductor wires bundled in a twisted state, the twisted structure forms a dead space and reduces the conductor space factor, or a local coil is formed and an eddy current is formed. Will occur.

  This invention is made | formed in view of this point, The place made into the objective is to manufacture the assembly conductor which can suppress generation | occurrence | production of an eddy current and can improve a conductor space factor. .

In order to achieve the above-mentioned object, the present invention provides a conductor wire bundle formed by bundling a plurality of conductor wires each having a partial cross-section of the entire cross-sectional shape in a non-twisted state. Each conductor wire is integrated in the pressed state .

Specifically, the method for producing an aggregate conductor according to the present invention is a method for producing an aggregate conductor in which a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the overall cross-sectional shape are integrated in an untwisted state. A conductor wire bundle forming step of forming a conductor wire bundle having a rectangular cross section by bundling the conductor wires having a binding layer formed on the surface thereof in a non-twisted state, and for passing through the conductor wire bundles, respectively. A step of preparing a pair of straightening jigs having a rectangular through hole, and an integration step of integrating the conductor wires through the binding layer in a state where the conductor wire bundle is pressed from the side. In the integration step, the conductor wire bundle is advanced from the through hole of the one correction jig to the through hole of the other correction jig, thereby pressing the two adjacent side surfaces of the conductor wire bundle, respectively. together forming the respective conductor lines state Characterized in that it.

According to the above method, in the conductor wire bundle forming step, a conductor wire bundle is formed by bundling a plurality of conductor wires each having a cross section of a part of a shape obtained by dividing the entire cross sectional shape of the collective conductor in an untwisted state, Thereafter, in the integrating process, because integrating the respective conductor wires while pressing the conductor wire bundles from the side, between the conductor lines are closely bound via a binder layer, conductor space in the set conductor The volume factor is improved. Moreover, since each conductor wire which comprises an assembly conductor is integrated in an untwisted state, a local coil is not formed and generation | occurrence | production of an eddy current is suppressed. Therefore, an assembly conductor capable of suppressing the generation of eddy current and improving the conductor space factor in the assembly conductor is manufactured.

  Moreover, according to said method, since the adjacent two side surfaces in the conductor wire bundle which has a rectangular cross section are pressed, a conductor wire bundle is pressed inward and each conductor wire is tightly bound.

  Further, according to the above method, the conductor wire bundle is bound between the pair of correction jigs, so that the conductor wires are bound to each other while maintaining the aligned state of the conductor wires in the conductor wire bundle.

  In the integration step, two adjacent inner surfaces constituting the rectangular through hole of each correction jig may be brought into contact with two adjacent side surfaces of the conductor wire bundle.

  According to said method, two adjacent side surfaces of a conductor wire bundle are pressed by two adjacent inner surfaces in the through-hole of each correction jig.

  The radius of curvature of the corner portion of the rectangular through hole of each of the correction jigs may be smaller than the radius of curvature of the corner portion of the conductor wire bundle.

  According to said method, the floating of the corner | angular part of the conductor wire which comprises the conductor wire bundle in the rectangular through-hole of each correction jig or a conductor wire bundle is suppressed.

  The integration step may include a four-direction pressing step for pressing each side surface of the conductor wire bundle.

  According to the above method, since each side surface of the conductor wire bundle is pressed in the four-direction pressing step of the integration step, variation in the overall cross-sectional shape of the assembly conductor is suppressed, and the conductor wires are bound to each other. Variation in binding force is suppressed.

  Each of the conductor wires includes a conductor wire having a rectangular cross section, an insulating coating layer provided so as to cover the conductor wire, and the binding provided so as to cover the coating layer And a layer.

  According to said method, since the cross section of the conductor strand which comprises a conductor wire is a rectangular shape, the cross section of a conductor wire also becomes a rectangular shape. Therefore, by superimposing the side surfaces of each conductor wire, each conductor wire is easily aligned in the width direction and height direction with each conductor wire insulated by the covering layer. The rate can be improved.

  In an electric vehicle using an inverter-driven motor, it is desired to improve a conductor space factor inside a slot of a stator core constituting the motor in order to increase the efficiency of the motor. Therefore, the present invention is particularly effective for an inverter-driven motor coil.

According to the present invention, respectively, each of the conductor wire bundles formed by bundling a plurality of conductor lines having a cross section in the shape of a portion obtained by dividing the entire cross-sectional shape in the untwisted state in a state of pressing from the side Since the conductor wires are integrated, it is possible to manufacture an aggregate conductor that can suppress the generation of eddy currents and improve the conductor space factor.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited to the following embodiment.

Embodiment 1 of the Invention
1 to 8 show Embodiment 1 of a method for manufacturing an aggregate conductor according to the present invention.

  FIG. 1 is a perspective view of the collective conductor 10 according to the present embodiment.

  As shown in FIG. 1, the assembly conductor 10 has a plurality of conductor wires 3 integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state. The conductor wires 3 are bound to each other by a binding layer 4 formed on the surface. Here, the term “integration” means that there is no contact interface between the binding layers 4 of the adjacent conductor wires 3.

  The conductor wire 3 has a linear conductor element wire 1 having a rectangular cross section, an insulating covering layer 2 provided so as to cover the conductor element wire 1, and a covering layer 2. And a binding layer 4 provided. The rectangular cross-sectional shape of the conductor wire 3 (conductor wire 1) is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10.

  Here, the rectangular shape that is the cross-sectional shape of the conductor wire 1 (and the conductor wire 3) is a shape as shown in FIGS. 8 (a) to 8 (e). That is, the rectangular shape has a square cross section with a right corner as shown in FIG. 8A, a cross section rectangle with a right corner as shown in FIG. 8B, and FIG. 8C. As shown in FIG. 8D, the cross-sectional square whose corner is R, the cross-sectional rectangle whose corner is R as shown in FIG. The shape (parallel cross-section track shape) etc. which are parallel and the other is arc shape are included.

  Each of the shapes shown in FIGS. 8A to 8E can be formed by forming a conductor bus as a wire drawn by a die, or by a forming apparatus such as roller rolling.

  Moreover, what is necessary is just to process and shape the rolling shape of a round-shaped bus-bar from one direction in the cross-sectional track shape of FIG.8 (e).

  The cross-sectional shape of the conductor wire 1 is preferably the above rectangular shape from the viewpoint of space factor and productivity, but may be a polygon such as a triangle or a hexagon. Further, since the conductor wire 1 having a rectangular cross section is a rectangular wire having a relatively small surface area, the area occupied by the coating layer 2 can be reduced, and can be adapted to the collective conductors 10 of various sizes. it can. Further, in the conductor wire 1 having a rectangular cross section, the length of the long side is set to 1 to 1.5 times (preferably 1 to 1.2 times) the short side, so that m rows n When arranged in columns (m and n are natural numbers, for example, 3 rows and 6 columns as shown in FIG. 1), the conductor space factor is improved and an insulated conductor having a large surface area is obtained. It is possible to realize a reduction in size and weight of a motor (including a conductor wire through which high-frequency alternating current flows) used in the above. Note that the cross-sectional shapes of the conductor wires 1 constituting the assembly conductor 10 may not all be the same.

The size of the conductor wire 1 may be, for example, a size having a side of 0.05 mm to 2 mm (preferably 0.05 mm to 1 mm) and corresponding to a round wire of 0.03 mmφ to 2.0 mmφ. as is a 0.0007mm ² ~4mm ^2.

  The conductor wire 1 is made of a conductive material such as copper, aluminum, silver, iron, gold, or an alloy thereof.

  Examples of the material of the coating layer 2 include those formed by dip coating, such as polyamideimide, polyesterimide, polyester, urethane, acrylic, epoxy, polyimide, and polyvinyl formal resins. Examples of the resin formed by electrodeposition coating include acrylic, polyester, polyimide, epoxy, and urethane resins. In particular, when heat resistance is taken into consideration, resins such as polyimide and polyamideimide are preferable. Moreover, when considering the connectivity by solder, urethane-based resin that is easily thermally decomposed is preferable. Furthermore, when considering the followability due to deformation such as bending, an acrylic resin is preferable. The covering layer 2 may be an oxide film obtained by oxidizing the surface of the conductor wire 1.

The film thickness of the coating layer 2 is 1 μm to 5 μm (preferably 1 μm to 3 μm) in the case of electrodeposition coating, and 1 μm to 10 μm in the case of dip coating. Here, in the case of electrodeposition coating, since a uniform thin film of about 1 μm can be formed on the surface of the conductor wire 1, the cross-sectional area of the coating layer 2 is reduced, and the conductor space factor in the conductor wire 3 is reduced. Can be improved. Moreover, in the case of electrodeposition coating, the coating layer 2 can be reliably formed also in the corner | angular part of the conductor strand 1. FIG. Specifically, since the covering layer 2 having a thickness equivalent to that of the central portion is easily formed at the end in the width direction of the conductor wire 1, without reducing the conductor space factor in the collective conductor 10, The insulation between each conductor wire 1 in the assembly conductor 10 can be improved. Furthermore, as shown in FIG. 2, greater than the thickness d ₁ of the covering layer 2 of the central part edge in the width direction of the conductor wire 1 the thickness d ₂ of the coating layer 2 in (corners) in the width direction It may be formed. In this case, the thicknesses d ₁ and d ₂ are 5 μm to ₁₀ μm. According to this, since the covering layer 2 at the corners of the conductor wire 1 is reinforced, the insulation between the conductor wires 1 in the collective conductor 10 can be improved. In addition, when high pressure resistance is not calculated | required, the coating layer 2 does not need to be uniformly formed in the surface of the conductor strand 1. FIG.

  As the binder layer 4, as a fusing material, a resin having heat fusibility such as polyvinyl butyral, polyamide, epoxy, or polyester, or alcohol fusibility such as polyamide that has been modified to be soluble in alcohol is used. Examples of adhesives include EVA, acrylic, urethane, epoxy, chloroprene, cyanoacrylate, silicone, nitrile, PVC, and vinyl acetate resins. In addition, since the binder layer 4 is comprised with the above resin, the insulation between each conductor strand 1 in the assembly conductor 10 can also be improved.

  The film thickness of the binder layer 4 is 0.5 μm to 3 μm. Here, the binding layer 4 may not be uniformly formed on the surface of the conductor wire 3 as long as each conductor wire 3 can be fixed in the collective conductor 10.

  When pressure resistance is required for the outermost layer of the collective conductor 10, a tape having insulating properties such as polyimide, aramid, polyester, and nylon is wound around the surface of the collective conductor 10 or covered. The same resin as layer 2 may be dip-coated.

  As shown in FIG. 3, the assembly conductor 10 having the above configuration is arranged in a plurality of layers (for example, four layers) inside each slot 30 b of the stator core 30 constituting the motor. According to this, it is possible to suppress the formation of a dead space inside the slot as in the case where a plurality of conductor wires 103 having a circular cross section are arranged (see FIG. 14). Here, the stator core 30 is formed in a cylindrical shape, and includes a plurality of protrusions 30a and recesses (slots 30b) formed alternately in the circumferential direction on the inner peripheral wall or outer peripheral wall thereof. In FIG. 3, the curved stator core 30 is replaced with a flat surface, but the slot 30b has, for example, a width of the bottom portion of about 4 mm, a width of the opening portion of about 6 mm, and a depth. Is about 30 mm.

  Next, an example is given and demonstrated about the manufacturing method of the assembly conductor 10 of the said structure. Here, the collective conductor 10 is manufactured using the collective conductor manufacturing apparatus 50a shown in the top view of FIG. 4 and the side view of FIG.

  In this assembly conductor manufacturing apparatus 50a, a plurality of unwinding rolls 20, a sheep 26, a first guide roll 21, a first die 22a, a binding treatment chamber 23, a second die 22b, and a second guide roll. 24 and the winding roll 25 are provided so that it may continue in a line.

  Each unwinding roll 20 is configured so that an equivalent back tension can be applied to the unwound conductor wire 3. As a result, tension is applied to the conductor wire 3 supplied from each unwinding roll 20 to the first die 22a via the sheep 26 and the first guide roll 21, so that each conductor wire is placed inside the first die 22a. 3 can be arranged in an aligned state.

  The sheep 26 is a pulley with a groove for removing twists and bends of the conductor wire 3.

  The first guide roll 21 guides the conductor wire 3 unwound from each unwinding roll 20 to the first dice 22a.

  As shown in FIG. 6, the first die 22 a and the second die 22 b are arranged in the width direction and the height direction by connecting a plurality of conductor wires 3 formed on the surface with the binding layer 4 supplied from the first guide roll 21. It is a pair of correction jigs for correcting the aligned conductor wire bundle 5. FIG. 6 is a cross-sectional view of the first die 22a taken along the line VI-VI in FIG.

  Further, the first die 22 a and the second die 22 b have a through hole H having a rectangular cross section for allowing the conductor wire bundle 5 to pass therethrough. Further, the clearance (for example, 0.1 mm) between the inner surface of the through hole H of the second die 22b and the side surface of the conductor wire bundle 5 is between the inner surface of the through hole H of the first die 22a and the side surface of the conductor wire bundle 5. It is smaller than the clearance (for example, 0.5 mm).

  Further, as shown in FIGS. 4 and 5, the central axis Ad of the first die 22a and the second die 22b is in the left-right direction (width direction of the conductor wire bundle 5) and the vertical direction ( It is slightly shifted in the height direction of the conductor wire bundle 5. For example, when the production line speed (molding speed) is 1.0 m / second and the distance between the first die 22a and the second die 22b is 1.0 m, the central axis Ad of the first die 22a and the second die 22b is The vertical and horizontal directions are offset by about 0.5 cm from the center axis Al of the production line. According to this, the two adjacent inner side surfaces constituting the through holes H of the first die 22a and the second die 22b abut on the two adjacent side surfaces of the conductor wire bundle 5, and the conductor wire bundle 5 is connected to each through hole H. In FIG. 6, the conductor wire bundle 5 is adjacent to each other by two adjacent inner side surfaces in the through holes H of the first die 22a and the second die 22b, as shown in FIG. Two side surfaces can be pressed by the pressing force F.

  Further, the radius of curvature R2 (for example, 0.01 mm) of the corner C of each through hole H of the first die 22a and the second die 22b is an angle of the conductor wire bundle 5 (conductor wire 3) as shown in FIG. It is smaller than the curvature radius R1 (for example, 0.05 mm) of the part C. According to this, the floating of the corner portion C of the conductor wire bundle 5 at the corner portion C of each through hole H of the first die 22a and the second die 22b can be suppressed, and the alignment of the conductor wires 3 in the conductor wire bundle 5 can be suppressed. The state can be maintained.

  The binding processing chamber 23 is for binding the conductor wires 3 constituting the conductor wire bundle 5. Here, the binding processing chamber 23 in the case of using a heat-fusible bonding material as the bonding layer 4 includes a heater for heating the conductor wire bundle 5. Further, the binding processing chamber 23 in the case of using a fusion material having alcohol fusion properties as the binding layer 4 includes a coater for applying alcohol to the conductor wire bundle 5. Further, in the case of using an adhesive as the binding layer 4, the binding processing chamber 23 heats the conductor wire bundle 5 with a coater for applying the adhesive to the conductor wire bundle 5, and dries (hardens) the applied adhesive. ) Heater.

  The second guide roll 24 guides the collective conductor 10 supplied from the second die 22 b to the take-up roll 25.

  Below, the assembly conductor manufacturing apparatus 50a having the above-described configuration is prepared, and a method for manufacturing the assembly conductor 10 in the case where a fusion material having heat fusion properties is used as the binding layer 4 is described.

  First, the surface of the conductor wire 1 having a rectangular cross section was coated with an epoxy-modified acrylic resin-based water-dispersed varnish and then dried and baked to provide a coating layer 2 on the surface. Conductor wire 3 is formed.

  Subsequently, an epoxy varnish is dip-coated on the surface of the conductor wire 3 to form a binding layer 4 on the surface. At this time, the conductor wire 3 on which the binding layer 4 is formed is wound around a plurality of unwinding rolls 20.

  Further, each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50a, the conductor wire 3 is unwound from each unwinding roll 20, and passed through the sheep 26 and the first guide roll 21, as shown in FIG. The plurality of conductor wires 3 are arranged in an aligned state inside the first die 22a to form the conductor wire bundle 5, and the tip of the conductor wire bundle 5 is sent to the inside of the second die 22b (conductor wire bundle forming step).

  Next, the binding processing chamber 23 is operated to heat the conductor wire bundle 5. At this time, the conductor wires 3 adjacent to each other in the conductor wire bundle 5 are fused and integrated with each other to obtain the collective conductor 10 (integration step). According to this, since the conductor wire bundle 5 is integrated between the first dice 22a and the second die 22b, the conductor wire bundles 5 constituting each conductor wire bundle 5 are maintained while maintaining the alignment state of the conductor wires 3 in the conductor wire bundle 5. The conductor wires 3 can be bound to each other.

  Finally, the assembly conductor 10 is wound around the winding roll 25 via the second guide roll 24.

  As described above, the assembly conductor 10 can be manufactured.

As described above, according to the method of manufacturing the collective conductor 10 of the present embodiment, in the conductor wire bundle forming process, each conductor wire 3 constituting the collective conductor 10 divides the rectangular overall cross-sectional shape of the collective conductor 10. The side surfaces of the conductor wires 3 are overlapped in a state where the conductor wires 1 constituting the conductor wires 3 are insulated from each other by the coating layer 2. Thus, the conductor wire bundle 5 is formed, and then, in the integration step, the conductor wires 3 are integrated in a state where the conductor wire bundle 5 is pressed from the side by the first die 22a and the second die 22b. The lines 3 are tightly bound via the binding layer 4, and the conductor space factor in the collective conductor 10 can be improved. Moreover, since each conductor wire 3 which comprises the assembly conductor 10 is integrated in an untwisted state, a local coil is not formed and generation | occurrence | production of an eddy current can be suppressed. Therefore, it is possible to manufacture the collective conductor 10 that can suppress the generation of eddy currents and improve the conductor space factor.

  Moreover, since the assembly conductor 10 is configured by bundling a plurality of conductor wires 3, the skin current is divided, and eddy currents are canceled between adjacent conductor wires 3, so that the AC resistance can be lowered. Current loss can be reduced.

  Furthermore, in the collective conductor 10, since the coating layer 2 can be formed thin by electrodeposition coating, the conductor space factor in the collective conductor 10 and each conductor wire 3 is improved, and the motor efficiency can be increased.

  Further, since each conductor wire 3 is fixed by the binding layer 4 in the collective conductor 10, each conductor wire 3 can be held in an aligned state even when deformed by bending or the like. Since the assembly conductor 10 is easier to form than to form a plurality of single conductor wires by bundling them, it can be adapted to coils of various shapes.

  Furthermore, in the collective conductor 10, since each conductor wire 3 is bound by the binding layer 4 made of resin, the binding can be released by solvent treatment, heating, or the like.

  Further, since the collective conductor 10 is a rectangular wire having a rectangular cross section, it is easy to handle.

  Furthermore, in the present embodiment, for example, as shown in FIG. 1, a method of manufacturing an assembly 10 of 3 rows and 6 columns at a time is illustrated. However, the present invention includes, for example, 6 precursors of 3 rows and 1 column. That is, six columns may be manufactured, and then the six precursors may be stacked and bonded into a state of three rows and six columns to manufacture the assembly 10.

<< Embodiment 2 of the Invention >>
9 to 11 show Embodiment 2 of the method for manufacturing an aggregate conductor according to the present invention. Here, FIG. 9 is a top view of the collective conductor manufacturing apparatus 50b according to the present embodiment, and FIG. 10 is a side view of the collective conductor manufacturing apparatus 50b. FIG. 11 is a cross-sectional view partially showing the four-way roller die 22c constituting the assembly conductor manufacturing apparatus 50b. In the following embodiments, the same parts as those in FIGS. 1 to 8 are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIGS. 9 and 10, the assembly conductor manufacturing apparatus 50 b is provided with a four-way roller die 22 c between the first die 22 a and the binding processing chamber 23. In the collective conductor manufacturing apparatus 50b, the configuration other than the four-way roller die 22c is the same as that of the collective conductor manufacturing apparatus 50a described in the first embodiment.

  As shown in FIG. 11, the four-way roller die 22 c includes a first roller die 22 ca that contacts the upper surface of the conductor wire bundle 5, a second roller die 22 cb that contacts the lower surface of the conductor wire bundle 5, and the conductor wire bundle 5. A third roller die 22cc that contacts the left side surface and a fourth roller die 22cd that contacts the right side surface of the conductor wire bundle 5 are provided.

  The first roller die 22ca and the second roller die 22cb are formed in a rotatable columnar shape, and are configured such that the peripheral walls thereof are pressed against the upper side surface and the lower side surface of the conductor wire bundle 5 by the pressing force F.

  The third roller die 22cc and the fourth roller die 22cd are formed in a rotatable disk shape having a peripheral wall so that the peripheral wall presses against the left side surface and the right side surface of the conductor wire bundle 5 with the pressing force F. It is configured.

  When the assembly conductor 10 is manufactured using the assembly conductor manufacturing apparatus 50b having the above configuration, the conductor wire bundle 5 is connected to the first die 22a and the first die 22a in the integration step in the method of manufacturing the assembly conductor 10 described in the first embodiment. What is necessary is just to press each side surface of the conductor wire bundle 5, respectively, while making it integrate between 2 dice | dies 22b (4 direction pressing process).

  According to the manufacturing method of the collective conductor 10 of the present embodiment, each side surface of the conductor wire bundle 5 is pressed in the four-direction pressing step of the integration step, so that the entire cross-sectional shape (finished dimension) of the collective conductor 10 varies. In addition, it is possible to suppress variation in binding force that binds the conductor wires 3 to each other.

  In the present embodiment, the four-way roller die 22c is disposed between the first die 22a and the binding processing chamber 23. However, the four-way roller die 22c is disposed between the binding processing chamber 23 and the second die 22b. It may be arranged.

In the present embodiment , the conductor wire bundle 5 is integrated in a state where the conductor wire bundle 5 is pressed from the side by the first die 22a, the second die 22b, and the four-direction roller die 22c, but the first die 22a and / Or the second dice 22b may be omitted.

<< Other Embodiments >>
In the first and second embodiments, the collective conductor 10 in which the cross-sectional shape of the conductor wire 3 (conductor wire 1) is rectangular has been described. However, the present invention is not limited to each conductor wire as shown in FIG. 3 (conductor element wire 1) having a circular cross-sectional shape, and the conductor lines 3 are arranged vertically and horizontally, as shown in FIG. 13, and each conductor wire 3 (conductor element 3) The present invention can also be applied to a close-packed type collective conductor in which the cross-sectional shape of the line 1) is circular and the conductor wires 3 are arranged in a close-packed manner.

  As described above, the present invention can improve the conductor space factor in the collective conductor, and thus is useful as a coil conductor for a motor driven by an inverter.

1 is a perspective view of a collective conductor 10 according to Embodiment 1. FIG. 4 is a schematic cross-sectional view showing an example of a conductor wire 3 that constitutes the aggregate conductor 10. FIG. FIG. 4 is a cross-sectional view showing a state in which the aggregate conductor 10 is disposed inside a slot 30b of the stator core 30. It is a top view of the assembly conductor manufacturing apparatus 50a which manufactures the assembly conductor 10. FIG. It is a side view of the assembly conductor manufacturing apparatus 50a which manufactures the assembly conductor 10. FIG. It is sectional drawing of the 1st dice 22a along the VI-VI line in FIG. It is sectional drawing to which the corner | angular part (corner part) C in FIG. 6 was expanded. 2 is a cross-sectional view showing an example of a rectangular shape that is a cross-sectional shape of a conductor wire 1. FIG. It is a top view of the assembly conductor manufacturing apparatus 50b which manufactures the assembly conductor 10 which concerns on Embodiment 2. FIG. It is a side view of the assembly conductor manufacturing apparatus 50b which manufactures the assembly conductor 10. FIG. It is sectional drawing which shows partially the 4-direction roller die 22c which comprises the assembly conductor manufacturing apparatus 50b. It is sectional drawing of the 1st collective conductor which concerns on other embodiment. It is sectional drawing of the 2nd collective conductor which concerns on other embodiment. FIG. 5 is a cross-sectional view showing a state in which a conductor wire 103 having a circular cross section is arranged inside a slot 130b of a stator core 130.

C Corner (corner)
H Through-hole 1 Conductor element wire 2 Coating layer 3 Conductor wire 4 Binding layer 5 Conductor wire bundle 10 Collective conductor 22a First die (correcting jig)
22b Second die (correction jig)

Claims (6)

Each of which is a method of manufacturing a collective conductor in which a plurality of conductor wires having a cross-section of a part of a shape obtained by dividing an overall cross-sectional shape are integrated in a non-twisted state,
A conductor wire bundle forming step of forming a conductor wire bundle having a rectangular cross section by bundling each conductor wire having a binding layer formed on its surface in a non-twisted state;
A step of preparing a pair of correction jigs each having a rectangular through-hole for penetrating the conductor wire bundle;
An integration step of integrating the conductor wires via the binding layer in a state where the conductor wire bundle is pressed from the side,
State above the integrating step, which by advancing the conductor wire bundles in the through hole of the other straightening jig from the through-hole of one of the straightening jig above, and the two side surfaces adjacent the conductor wire bundles to press each A method of manufacturing an aggregate conductor, wherein the conductor wires are bonded to each other. In the manufacturing method of the assembly conductor described in Claim 1,
In the integration step, the two adjacent inner side surfaces constituting the rectangular through hole of each correction jig are brought into contact with the two adjacent side surfaces of the conductor wire bundle. In the manufacturing method of the assembly conductor described in Claim 1 or 2,
The method of manufacturing an aggregate conductor, wherein a radius of curvature of a corner portion of the rectangular through hole of each of the correction jigs is smaller than a radius of curvature of a corner portion of the conductor wire bundle. In the manufacturing method of the assembly conductor described in Claim 1,
The method of manufacturing an aggregate conductor, wherein the integration step includes a four-direction pressing step of pressing each side surface of the conductor wire bundle. In the manufacturing method of the assembly conductor as described in any one of Claims 1 thru | or 4,
Each of the conductor wires includes a conductor wire having a rectangular cross section, an insulating coating layer provided so as to cover the conductor wire, and the binding provided so as to cover the coating layer And a method of manufacturing an aggregate conductor. In the manufacturing method of the assembly conductor as described in any one of Claims 1 thru | or 5,
The method of manufacturing an aggregate conductor, wherein the aggregate conductor is for an inverter-driven motor coil.

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