JP5316597B2 - Edgewise coil manufacturing method and edgewise coil manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a device for manufacturing an edgewise coil of high space factor which is not restricted for a small driving force, but applicable for a large driving force. <P>SOLUTION: This edgewise coil manufacturing device includes a winding part 21 of which the periphery surface has a rectangle cross section, a first flange 23 which has an internal peripheral surface touching the periphery surface of the winding part and a collar (flange) of the same height as a rectangular wire, and a first opposed flange 33 facing the first flange, a second flange 24 which has an internal peripheral surface touching a periphery surface of the first flange and a second opposed flange 34 facing the second flange. In the device, a space between the first flange and the first opposed flange and a space between the second flange and the second opposed flange are changeable. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to an edgewise coil manufacturing method and an edgewise coil manufacturing apparatus, and more specifically to an edgewise coil manufacturing method used for a motor used in an automobile and the like, and an edgewise coil manufacturing apparatus. Is.

A coil obtained by edgewise winding (vertical winding) of a wide rectangular wire has a better space factor and better heat dissipation than a coil having a circular cross section (round wire). Moreover, since a crossover process is not required at the time of coil formation, it has the merit that a coil winding process can be simplified. However, the edgewise winding method and apparatus for flat wires are more complicated than those for round wires. In particular, when used in a drive motor for an automobile that generates a large driving force, the manufacturing apparatus tends to be large and complicated. As an example of an edgewise coil for a small output, for example, an edgewise winding method and apparatus for a flat wire with a simple configuration has been proposed for a transformer for an igniter of a headlamp of an in-vehicle discharge lamp (patent) Reference 1). In this method, since both ends of the coil are sandwiched between the support surface of the winder and the contact surface of the fall-stopper, it is possible to reliably perform edgewise winding of a rectangular wire with a simple mechanism.
Japanese Patent Laid-Open No. 9-82551

  According to the above apparatus, an edgewise coil for generating a small driving force is possible. However, demands for edgewise coils and manufacturing apparatuses for applications that are not limited to small driving forces are increasing, particularly in the automotive field. In hybrid vehicles and electric vehicles, there is high expectation for edgewise coils having the above high space factor and capable of high drive output. The present invention provides a manufacturing method for manufacturing an edgewise coil having a high space factor, which is not limited to a small driving force but can also be applied to a large driving force, and an apparatus for manufacturing the edgewise coil. For the purpose.

  The edgewise coil manufacturing apparatus of the present invention manufactures a multi-layered edgewise coil by winding a single rectangular wire edgewise. In this manufacturing apparatus, a rectangular wire is wound and rotated around an axis, and the outer peripheral surface has a rectangular wire section having a rectangular cross section, and an inner peripheral surface in contact with the outer peripheral surface of the peripheral wire section, A flange having the same width (height) as a flange and an inner peripheral surface in contact with the outer peripheral surface of the winding portion, and having the same width as the flange of the first flange. It has a first opposing flange positioned so as to face the first flange, an inner peripheral surface in contact with the outer peripheral surface of the first flange, and a collar having the same width (height) as the flat wire. A second flange having an inner circumferential surface in contact with the outer circumferential surface of the first opposing flange, having a collar having the same width as the collar of the second flange, and facing the second flange A second opposing flange. The distance between the first flange and the first opposing flange can be changed, the distance between the second flange and the second opposing flange can be changed, and the first flange and the second flange can be changed. The flange can be aligned at the same position on the axis, and the first opposed flange and the second opposed flange can be aligned at the same position on the axis.

It is assumed that the above-described winding line portion, the first flange, the first opposing flange, the second flange, and the second opposing flange are cylindrical bodies. As for the first flange and the like other than the perforated line portion, the length of the cylindrical body may be extremely short, and literally, only the collar (rib) may be used. The width of the collar (rib width) or the height of the collar may be the thickness of the end face of the cylindrical body, or may be the protruding width of the portion (raft) that projects to the end of the cylindrical body.
In the above configuration, the first layer of the multi-layer edgewise coil can be formed by winding a rectangular wire around the line portion between the first flange and the first opposing flange. At that time, the first opposing flange is fixed, and the turn of the rectangular wire can be prevented from falling by winding the new turn between the immediately preceding turn and the retracted first flange. . During this rolling, the first flange moves backward so as to increase the distance from the first opposing flange.
When the first layer is wound, the distance between the first flange and the first opposing flange is kept constant, and a distance is applied so that a predetermined pressure is applied so that the first layer coil does not collapse. The second flange is fixed, and when a second layer is formed by winding a flat wire on the first layer coil, a new turn is inserted between the immediately preceding turn and the second opposing flange that moves backward. Make it. Since the flat wire of the new turn is sandwiched between the immediately preceding turn and the second opposing flange, the flat wire is prevented from falling.
According to the above manufacturing apparatus, it is possible to reliably manufacture two or more edgewise coils that are divided into half and spread in a rectangular shape with a small force without increasing the width of the rectangular wire. For this reason, an edgewise coil for high driving force that maintains a high space factor can be efficiently manufactured with a simple device having a small capacity (small load) without using a large-scale device.
In addition to the above-described components, this manufacturing apparatus, when winding a flat wire, is a roller that presses the flat wire toward the rectangular corner portion of the cut wire portion, or a tension greater than a predetermined value on the flat wire. You may provide the tension | tensile_strength addition apparatus etc. to add. By adding these auxiliary devices, a larger edgewise coil can be manufactured more reliably and efficiently.

  Said 1st flange can be fixed to one end of this line part. Thereby, the number of parts can be reduced and the structure of the manufacturing apparatus can be simplified. In the case of this structure, when the first flange moves in the axial direction while the distance between the first flange and the first opposing flange is increased (while retreating), the first layer of the edgewise coil (the first sleeve) 1).

By using the first flange and the second flange as a continuous integral body, an edgewise coil having a two-layer rectangular cross section can be manufactured. In the case of this structure, when winding the second layer, the first flange, the second flange, and the first opposed flange are kept at a constant distance (the first layer coil is already in between), and the first flange It is necessary to change the distance between the second flange and the second opposing flange. To that end, either (c1) move only the second opposing flange relative to the stationary first flange or the like, or (c2) move the entire first flange relative to the stationary second opposing flange, etc. That's fine.
In the case of (c2), when the first layer is wound, the winding line portion, the first flange, and the first opposing flange, including the first layer coil, are accommodated in the second opposing flange. Move. A second layer is formed between the second opposing flange and the second flange. At this time, the entire first flange and the like are moved backward with respect to the second opposing flange. The new turn can be prevented from falling over the flat wire by winding while turning between the immediately preceding turn and the second opposing flange.
Regardless of (c1) and (c2), this configuration can reduce the number of parts and simplify the mechanism of the manufacturing apparatus.

  An apparatus for manufacturing an edgewise coil having a two-layered rectangular cross section, wherein the above-described winding line portion has an inner peripheral surface that is penetrated by a composite shaft having a circular cross section and is in contact with the outer peripheral surface of the composite shaft. The composite shaft includes a core shaft and a cylindrical shaft that inscribes the core shaft. The outer peripheral surface of the cylindrical shaft and the inner peripheral surface of the winding line portion have a first threaded portion that is screwed. By rotating the cylindrical shaft, the winding line portion is in the axial direction with respect to the first opposing flange. Move relative. Further, the core shaft and the second opposing flange are screwed together, and by rotating the core shaft, the winding portion, the first flange, and the first opposing flange are relative to the second opposing flange in the axial direction. It can be moved and configured. As a result, the level of automation can be increased, and an edgewise coil having two or more layers can be reliably manufactured with high accuracy and high efficiency.

Another edgewise coil manufacturing apparatus according to the present invention protrudes in a cylindrical shape from a fixed portion for manufacturing a two-layer rectangular edgewise coil by winding one rectangular wire edgewise. It is a manufacturing device. The manufacturing apparatus includes a second opposing flange having a rectangular cross-section inner surface protruding from the fixed portion, and an axis line aligned with the center of the rectangular cross-section of the inner peripheral surface of the second counter flange, and the core shaft and the core shaft. A composite shaft consisting of a cylindrical shaft circumscribing the inner peripheral surface, and a screw provided in the cylinder of the second opposing flange so as to be freely movable in the axial direction and penetrating the composite shaft and provided on the outer peripheral surface of the cylindrical shaft A perforated line flange having a female thread to be screwed on the inner peripheral surface, and a rectangular cross section, the outer peripheral surface of the second opposing flange is slidably in contact with the inner peripheral surface, and the inner peripheral surface is rolled And a first opposing flange that is slidably in contact with the outer peripheral surface of the line flange. The composite shaft passes through the cylinder of the second opposing flange, the core shaft is screwed into a female screw provided in the fixed portion, and the winding portion flange is within the rectangular cross section of the second opposing flange. Has a rectangular cross-section outer peripheral surface with a space of one flat wire width between itself and the peripheral surface, and has a width (height) of at least twice the width of the flat wire at the tip opposite to the fixed part The first opposing flange has a rectangular cross section with a distance (thickness) between the inner peripheral surface and the outer peripheral surface equal to one flat wire width, and is fixed on the opposite side of the flanged portion flange. In the part on the part side, the inner peripheral surface is spaced from the outer peripheral surface of the cylindrical shaft by a width of one flat wire, and the core shaft has no screw part screwed with the fixed part and no screw without a screw. It has a collar for engaging and forcibly moving the cylindrical shaft and the end of the first opposing flange at the boundary with the part That.
With this configuration, the number of parts can be reduced and the mechanism of the manufacturing apparatus can be simplified.

The manufacturing method of the edgewise coil of the present invention uses a manufacturing apparatus for any of the edgewise coils that does not have the above-described composite shaft, and turns one rectangular wire edgewise to produce a multilayer, rectangular shape. This is a method of manufacturing an edgewise coil. In this manufacturing method, when winding the turn of the inner circumferential layer, one of the first flange and the first opposing flange is fixed and the other is retracted, and the rectangular wire already wound edgewise is retracted. When the start of rolling the outer peripheral layer is started after the turn is wound so that the rectangular wire is interrupted between the other flange and the predetermined turn is wound and the inner peripheral layer is rolled. While fixing the flange and the first opposing flange, and fixing one of the second flange and the second opposing flange to the front end surface of the flange that has been retracted, while retracting the other from the fixed flange, First, roll the rectangular wire into the gap between the fixed flange and the retreating flange, and then turn between the flat wire of the already wound turn and the retreating flange. And wherein the turning sown as to interrupt the flat wire of the next turn in the gap.
Accordingly, it is possible to easily and surely manufacture an edgewise coil having two or more layers that are divided into small portions and spread in a rectangle with a small force without increasing the width of the rectangular wire. Moreover, no circulating current is generated.

Another edgewise coil manufacturing method according to the present invention is to manufacture a two-layer edgewise coil by winding one rectangular wire edgewise using the edgewise coil manufacturing apparatus having the composite shaft described above. It is a way for. In this manufacturing method, at the start of winding of the first layer of the two-layer rectangular edgewise coil, the flange of the winding wire portion flange is a gap corresponding to one flat wire thickness from the tip surface of the second opposing flange. The flat wire is wound around for one turn so that the flat wire is inserted into the gap, and then, in the second turn, the core shaft and the cylindrical shaft are rotated so that the wire flange is The flat wire of the first turn is forcibly moved by sliding it on the outer peripheral surface of the flange of the winding wire portion and forcibly moving the flat wire of the first turn toward the fixed portion. An edgewise coil consisting of the first layer is rotated by turning the core shaft and the cylindrical shaft after winding the first layer that has been wound around the intended turn and after the end of the desired turn. Is accommodated in the cylinder of the second opposing flange, The distance between the tip of the die and the flange of the winding wire portion flange is turned around for the first turn so that a flat wire with a thickness corresponding to one thickness is opened, and then the flat wire is interrupted. The second turn rectangular wire is inserted between the first turn rectangular wire and the front end surface of the second opposing flange while the heel is rotated backward from the fixing portion.
Thus, a two-layer rectangular edgewise coil can be easily and easily manufactured by an apparatus having a small number of parts. Moreover, no circulating current is generated.

  According to the present invention, it is possible to obtain a method for manufacturing an edgewise coil having a high space factor, which is applicable not only for a small driving force but also for a large driving force, and an apparatus for manufacturing the edgewise coil. it can.

(Embodiment 1)
FIG. 1 is a diagram showing an edgewise coil 10 manufactured by an edgewise coil manufacturing method and an edgewise coil manufacturing apparatus according to Embodiment 1 of the present invention. FIG. 2 is a diagram showing a state where the split core 71 is inserted into the edgewise coil 10 to form the split stator 60 and further assembled to the stator 70. The stator 70 is formed by arranging the divided stator 60 on the circumference.
In the following description, the item of the manufacturing method is not provided, but as will be seen later, the manufacturing method is explained naturally and in detail while explaining the operation procedure of the manufacturing apparatus and the function of each part of the manufacturing apparatus. go. The same applies to the second embodiment.
The edgewise coil 10 is a two-layer coil of an inner layer L1 and an exterior L2, and is formed by only one flat wire 1. Both the inner layer side terminal 11 and the outer layer side terminal 12 corresponding to both ends of one flat wire 1 are located at the end portion on the back yoke side of the coil (see the back yoke 71a in FIG. 2). One flat wire 1 starts to be wound from the inner layer side terminal 11, and is wound from the inner layer L1 to the outer layer L2.
The flat wire is formed from copper and a coating layer covering the copper. Usually, enameled wire is used, but it may not be enameled wire. Any copper may be used as long as it is used for coils, electrical wiring, etc., but it is preferable that the electrical resistance is low. Moreover, the rectangular wire manufactured with what kind of manufacturing method may be sufficient.
A layer rising portion Lm is formed at a position where the inner layer L1 moves to the outer layer L2. In FIG. 1, the layer rising portion Lm is located at the corner portion C of the coil. The coil wound in a rectangular shape includes a coil side portion S parallel to the direction in which both terminals extend or parallel to the long side of the rectangle, a coil end portion E parallel to the short side of the rectangle, and a rectangular corner. The corner portion C is formed in a rounded shape corresponding to the position. The coil axis is along the direction connecting the back yoke side and the rotor side.

−Point of edgewise coil of this embodiment−
The edgewise coil shown in FIG. 1 has the following features (1) to (4).
(1) One flat wire is wound in two layers.
(2) It is wound around a rectangle.
(3) The rising part is located at the corner of the coil.
(4) Both terminals 11 and 12 are both located at the end on the back yoke side.

(1) About two-layer winding of a single rectangular wire (a1) A high magnetic flux density can be generated, and it can be used for a high driving force. In addition, (a2) the rectangular wire that is the winding can be divided in the width direction, the bending radius can be reduced, and downsizing can be realized. Moreover, (a3) The capacity | capacitance (power) of a coil winding apparatus can be made small by winding the width | variety of a flat wire into a multilayer, and dividing | segmenting a width | variety into the number of the layers.
In summary, according to the above (a1) to (a3), a coil for generating a high driving force can be easily maintained without using a large wire-drawing device while maintaining a high space factor specific to an edgewise coil. Can be manufactured. Further, (a4) eddy current loss during use can be reduced.
For one flat wire, the following advantages and disadvantages occur. (Advantage) By using a single rectangular wire to wrap around in multiple layers, there is no circulating current that poses a problem in a multilayer edgewise coil with a plurality of parallel rectangular wires. (Disadvantage) At the end where the flat wire moves from the inner layer to the outer layer, the layer rising portion Lm is always formed. The layer rising portion Lm slightly lowers the space factor, but the degree of the decrease is slight, and a high space factor peculiar to the rectangular wire edgewise coil can be maintained.
(2) About the rectangle In the edgewise coil 10, the flat wire 1 is wound in a rectangle. As a result, when the stator 70 is configured by the edgewise coil as shown in FIG. 2, the rectangular short side is a predetermined number while the edgewise coils 10 are densely arranged along the outer circumferential direction of the rotor. The length is such that the edgewise coil 10 is arranged. In FIG. 2, twelve edgewise coils 10 are arranged at the rotor side end portion without overlapping and without a gap.
In addition, the length of the long side of the rectangle determines how long the region of high magnetic flux density is arranged in the axial direction of the rotor. That is, long magnetic fluxes can be arranged in the axial direction of the rotor by increasing the length of the long side of each rectangular edgewise coil. For this reason, according to the diameter of a rotor and required torque, along with other factors (electric current value etc.), the leading factor for giving a required driving force to a rotor can be constituted.
(3) Regarding the position of the layer rising portion Lm In particular, by disposing the layer rising portion in the corner portion C or the coil end portion E other than the coil side portion, the decrease in the space factor due to the layer rising is minimized. Can do. The reason will be described with reference to FIG. If the layer rising portion Lm is positioned on the coil side portion S, the coil position corresponding to the layer rising portion Lm extends in the coil axis direction by the thickness of the rectangular wire and becomes longer. As a result, in the stator 70 shown in FIG. 2, the adjacent edgewise coils overlap with each other on the rotor side end. For this reason, in order to arrange all the edgewise coils in the form of FIG. 2 without overlapping, the length of each edgewise coil in the coil axis direction must be reduced. As a result, the number of turns must be reduced and the magnetic flux density is reduced.
When the layer rising portion Lm is located at the corner portion C or the coil end portion E, adjacent divisions at the end portion on the rotor side of the edgewise coil 10 even if the stator 70 as shown in FIG. 2 is formed. The overlap between the stators 60 is not affected. For this reason, the layer rising portion Lm is positioned at the corner portion C or the coil end portion E.
(4) Position of terminal The number of layers of the edgewise coil shown in FIG. 1 is 2, which is an even number. For this reason, both terminals corresponding to both ends of one rectangular wire can be positioned on the back yoke 71a side as shown in FIG. As a result, wiring when assembled to the stator 70 can be performed easily. In FIG. 2, when three-phase AC power is supplied, for example, four U1, U2, U3, U3, and U4 divided stators 60 are connected in series. The connection is the same in the V phase and the W phase. Since both ends 11 and 12 are located on the back yoke side, the above-described wiring connection can be easily performed.

Next, the manufacturing apparatus 50 of said edgewise coil 10 is demonstrated. FIG. 3 is a diagram illustrating a state in which the first layer L1 is being rolled using the manufacturing apparatus 50. In FIG. 3, the winding wire portion 21 is rotating, and the flat wire 1 is wound around the winding wire portion 21 for two turns t ₁ and t ₂ . As the number of turns increases, the first flange 23 moves backward. The new turn is inserted to interrupt between the immediately preceding turn t ₂ and the first flange 23. The first opposing flange 33 is in a fixed state. The first flange 23 and the first opposing flange 33 are tubular bodies, and the collar width or the collar height is equal to the thickness d of each tubular body. The contact surfaces of the edge-wise coils of the first flange 23 and the first opposing flange 33 to the rectangular wire 1 are end surfaces of the respective cylindrical bodies. Within a substantial range, the width (height) of the flat wire 1 is equal to the thickness d of the cylindrical bodies 23 and 33.

Next, as shown in FIG. 4, the second layer L2 is rolled. After rolling the 1st layer L1, the 1st flange 23 and the 1st counter flange 33 are made into a fixed state, and keep the position which applies pressure to the 1st layer L1 so that collapse of the 1st layer L1 may be prevented. _Let t _{n be} the final turn of the first layer L1. The second flange 24 located on the first flange 23 side is in a fixed state while forming the above-mentioned layer rising portion on the first turn u ₁ of the second layer on the final turn t _n of the first layer. , Whisper. At this time, the second opposing flange 34 increases (retreats) the distance with respect to the second flange 24. In FIG. 4, a new turn u ₃ is formed by rolling the flat wire 1 between the immediately preceding turn u ₂ and the second opposing flange 34. Both the 2nd flange 24 and the 2nd opposing flange 34 are cylindrical bodies, and both widths are equal to the thickness of a cylindrical body.

  As described above, in both the first layer L1 and the second layer L2, a new turn is wound around so that the flat wire 1 is interrupted between the immediately preceding turn and the retreating flange. The fall can be prevented. For this purpose, flanges that define both end portions of the edgewise coil are prepared with different diameters for the first layer and the second layer. Accordingly, a two-layer edgewise coil using a rectangular wire can be easily manufactured using relatively small power.

In addition to the above-described winding line portion 21, the first and second flanges 23 and 24, and the first and second opposing flanges 33 and 34, for example, as shown in FIG. A roller 15 for facilitating rolling 1 may be arranged. The roller 15 is freely rotatable about the roller axis, and presses the supplied rectangular wire 1 against the corner portion C on the outer periphery of the winding wire portion 21. The arrangement of the rollers 15 makes it easy to wind the rectangular wire 1 edgewise in a rectangle.
In addition, it is preferable to arrange a tension maintaining device (not shown) in order to apply a tension of a predetermined value or more to the flat wire 1 at the time of rolling. Tension is applied to the flat wire 1 between the contact position of the roller 15 and a portion fed out from a bobbin or the like around which the flat wire 1 is wound. As the mechanism of the tension maintaining device, any commonly used mechanism such as a mechanism for projecting the rectangular wire 1 between the above to be deviated from the straight line shape can be used.

(Embodiment 2)
FIG. 6 is a cross-sectional view of the edgewise coil manufacturing apparatus 50 according to Embodiment 2 of the present invention, and FIG. 7 is a view of the edgewise coil manufacturing apparatus 50 of FIG. It is a front view. That is, another edgewise coil manufacturing apparatus 50 of the present invention having a composite shaft. In the edgewise coil manufacturing apparatus 50, the winding line portion, the first flange, and the second flange are integrated into the integral winding line portion flange 51. The flange portion or flange portion 51 f of the winding wire portion flange 51 defines the rotor side end portion of the edgewise coil 10. The line portion 21 in the first embodiment corresponds to the line portion 51 k of the line portion flange 51. In this way, the number of parts can be reduced by using the integrated lined flange 51, and the operation of the edgewise coil manufacturing apparatus 50 can be facilitated and automated as will be described later. You can also
In FIG. 6, the edgewise coil 10 is in a completed state in which the two layers L <b> 1 and L <b> 2 are wound around the winding wire portion flange 51.

In FIG. 6, the first facing flange 53 and the second facing flange 54 are positioned so as to face the flange portion (ridge) 51 f of the winding portion flange 51. The second opposing flange 54 is always in a stationary state (solid state). The composite shafts 55 and 56 include a core shaft 56 and a cylindrical shaft 55. The core shaft 56 is screwed with the second opposing flange 54, and by rotating the core shaft 56, the entire cylindrical shaft 55, the winding wire portion flange 51, and the first opposing flange 53 are secondly opposed. It can be stored inside the flange 54 or pulled out to the outside. The cylindrical shaft 55 is provided with a screw on its outer peripheral surface, and is screwed with a screw provided on the inner peripheral surface of the winding wire portion flange 51. By rotating the cylindrical shaft 55, the winding line flange 51 can be moved alone to the shaft tip side or moved to the shaft root side. In order to enable the above movement, spaces S1 and S2 must be provided.
As shown in FIG. 7, the winding line portion flange 51 has a rectangular cross section of the winding line portion 51k, and the flange portion 51f is provided so as to project outward from the end of the winding line portion 51k. The flange portion 51f is a combination of the first flange 23 and the second flange 24 in the first embodiment. Therefore, if the width of the flat wire 1 is d, the width (height) is 2d.

Next, the beginning of whirling of the first layer L1 will be described. FIG. 8 is a diagram showing the position of each part of the first layer L1 at the start of rolling. Portions other than the flange portion 51 f of the winding line portion flange 51, that is, the winding line portion 51 k are housed inside the first opposing flange 53. Such an arrangement is performed by rotating the cylindrical shaft 55 to move the winding portion flange 51 screwed into the cylindrical shaft 55 into the first opposed flange 53.
A gap between the flange portion 51f of the winding wire portion flange 51 and the first opposing flange 53 is set to an extent that one flat wire 1 is included. In this state, the space S1 is occupied by the line portion 51k and disappears.
The turning of the first layer L1 is started by the turning of the gap to the winding line portion 51k. As shown in FIG. 9, the next turn t2 is formed by rolling the flat wire 1 between the first turn t1 and the retreating flange portion 51f. At this time, the cylindrical shaft 55 is rotated so that the winding line portion flange 51 comes out of the first opposing flange 53 (retreats). That is, as the number of turns to be wound increases, the winding line portion flange 51 moves backward by one turn. The space S1 described above increases along with this.
At this time, the first turn t _1, the distance between the flange portion 51f will increase. This increase in distance, first turn t ₁ is made possible by slides seeded line portion 51k. Therefore, when the above-described integrated winding portion flange 51 is used, when a new turn is formed, the turns that have been wound up to that time are separated from the outer peripheral surface of the winding portion 51k for each new turn. It slides by the thickness of 1.

Figure 10 is a diagram showing a state where the first layer L1 is wound respectively by the above process, the final turn t _n are formed. Next, before rolling the second layer L2, as shown in FIG. 11, the core shaft 56 is rotated to include the core shaft 56, the cylindrical shaft 55, the winding wire portion flange 51, and the first facing. The flange 53 enters the inside of the second opposing flange 54. Since the first layer L1 is formed between the first opposing flange 53 and the flange portion 51f of the winding wire portion flange 51, the distance between both the portions 53 and 51f is kept constant. Due to the movement of the cylindrical shaft 55 and the like, the space S2 is greatly reduced. As a result, the gap between the second opposing flange 54 and the perforated wire portion flange 51f is about the thickness of one flat wire.

Then, as shown in FIG. 12, on the first layer L1, the first turn u ₁ of the second layer are wound respectively while forming a layer up unit described above. Then, the second turn u ₂ is formed by rolling the flat wire 1 between the first turn u ₁ and the second opposing flange 54. At this time, the winding wire portion flange 51 moves backward with respect to the second opposing flange 54 by rotating the core shaft 56 in the direction opposite to the above by the thickness of the flat wire 1. FIG. 6 shows a state where the same number of turns as the first layer L1 are formed and the turn of the second layer L2 is completed.

In addition to the above-described components, for example, as shown in FIG. 13, a roller 15 may be disposed to facilitate the winding of the rectangular wire 1 in a rectangular shape when it is rolled. The roller 15 is freely rotatable about the roller axis, and presses the supplied rectangular wire 1 against the corner portion C on the outer periphery of the winding wire portion 21. In order to hold the pressing force sufficiently high, a structure in which the support arm 44 that holds the roller 15 at the tip end is rotatably held on the support shaft 43 can be used. The support arm 44 is preferably provided with a slide portion 45 that can slide (slidably), and is provided with a braking portion 46 that pivots the slide portion 45 freely. Such an arrangement of the rollers 15 makes it easy to wind the rectangular wire 1 edgewise in a rectangular shape.
In addition, it is preferable to arrange a tension maintaining device (not shown) in order to apply a tension of a predetermined value or more to the flat wire 1 at the time of rolling. Tension is applied to the flat wire 1 between the contact position of the roller 15 and a portion fed out from a bobbin or the like around which the flat wire 1 is wound. As the mechanism of the tension maintaining device, any commonly used mechanism such as a mechanism for projecting the rectangular wire 1 between the above to be deviated from the straight line shape can be used.

According to the edgewise coil manufacturing apparatus 50 of the present embodiment, the following advantages can be further obtained while maintaining the operational effects of the manufacturing apparatus in the first embodiment.
(1) Since the winding line portion 21, the first flange 23, and the second flange 24 are integrated into a single winding line portion flange 51, the number of parts can be reduced.
(2) Since the number of parts that can be moved independently (flange) has been reduced, the number of parts to be controlled for movement is reduced. It has become possible to control the movement of the parts (flange) for preventing falling during turning. For this reason, automation in mass production can be facilitated.

  As described above, the flat wire 1 can be prevented from falling by rolling the new turn so that the flat wire 1 is inserted between the immediately preceding turn and the retreating flange. In particular, for the first layer, by performing the above winding while sliding the already wound turn with respect to the winding line portion 51k, while obtaining the reduction in the number of parts and the simplification of the movement, The flat wire 1 can be prevented from falling. Accordingly, a two-layer edgewise coil using a rectangular wire can be easily manufactured using relatively small power.

Next, when producing the 12-pole stator shown in FIG. 2, the edgewise coil of the present invention, the conventional edgewise coil, the shape of the normal coil, the winding, the winding form, etc., with specific numerical values. Introduced for comparison.
(Invention Sample A1): Coil size inner dimension 20 × 60 mm, number of turns 8, flat wire width 2.7 mm, thickness 4.4 mm (same form as edgewise coil (rectangular winding) in FIG. 1) Manufactured with the manufacturing apparatus of Form 2)
(Comparative Example B1): In the case of two parallel-wound edgewise coils (rectangular winding): Coil size inner dimension 20 × 60 mm, number of turns 16, flat wire width 2.7 mm, thickness 2.2 mm
(Comparative Example B2): In the case of one double-width rectangular wire (rectangular winding): Coil size inner dimension 20 × 60 mm, number of turns 16, flat wire width 5.4 mm, thickness 2.2 mm
(Comparative Example B3): In the case of one double-width rectangular wire (circular winding): coil size inner dimension 40 mm, number of turns 16, rectangular wire width 5.4 mm, thickness 2.2 mm
(Comparative Example B4): When forming a stator having the same volume with a round wire (rectangular winding): Coil size inner size 20 × 60 mm, number of turns 16, round wire diameter 3.9 mm
About each said coil, an evaluation test will be advanced with respect to the thing as it is, or the thing in which further miniaturization or enlargement was achieved.

As for the above-described edgewise coil manufacturing apparatus, only the two-layer edgewise coil manufacturing apparatus has been described. However, the edgewise coil of the present invention is not limited to two layers but may be three or more layers. There may be. In the case of the odd layer, both ends of one rectangular wire are divided into the back yoke side and the rotor side. In the case of the even layer, both ends can be on the back yoke side or the rotor side.
In the above embodiment, the case where the edgewise coil of the present invention is used for a stator of a three-phase AC motor has been described. However, the present invention is not limited to the stator for a three-phase AC motor, and is used for any other application. be able to.

  Although the embodiments and examples of the present invention have been described above, the embodiments and examples of the present invention disclosed above are merely examples, and the scope of the present invention is the implementation of these inventions. It is not limited to the form. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  According to the present invention, an edgewise coil having a high space factor that can be applied not only to a small driving force but also to a large driving force and a manufacturing apparatus thereof can be easily obtained by using a device having a relatively small capacity. be able to. In particular, the edgewise coil manufacturing equipment can reliably prevent the flat wire from falling down with a simple mechanism, and by integrating the moving parts, the movement control can be simplified and automation is easy. can do.

It is a perspective view of the edgewise coil manufactured with the manufacturing apparatus of the edgewise coil in Embodiment 1 of this invention, and the manufacturing method of the edgewise coil. It is sectional drawing for demonstrating the stator using the edgewise coil of FIG. It is a figure for demonstrating the manufacturing apparatus and manufacturing method of embodiment of this invention of the state which is winding the 1st layer of the edgewise coil of FIG. It is a figure for demonstrating the state which rolls the 2nd layer from the state of FIG. It is a figure for demonstrating the apparatus which has arrange | positioned the roller for making it easy to roll in a rectangle. It is sectional drawing for demonstrating the manufacturing apparatus of the edgewise coil in Embodiment 2 of this invention. It is the front view which looked at the manufacturing apparatus of FIG. 6 along the axis line from the shaft tip side. It is a figure for demonstrating the state at the time of starting to roll the 1st layer with the manufacturing apparatus of this Embodiment. FIG. 9 is a partial enlarged view of a line portion in FIG. 8. It is a figure which shows the state which rolled the 1st layer and completed the 1st layer in the manufacturing apparatus of this embodiment. It is a figure for demonstrating the state which starts rolling the 2nd layer following the state of FIG. It is a figure which shows the state which started rolling the 2nd layer from the state of FIG. In this Embodiment, it is a figure for demonstrating the apparatus which has arrange | positioned the roller for making it easy to roll in a rectangle.

DESCRIPTION OF SYMBOLS 1 Flat wire, 10 Edgewise coil, 11 Inner layer side terminal, 12 Outer layer side terminal, 15 Roller, 21 Peeling line part, 23 1st flange, 24 2nd flange, 33 1st opposing flange, 34 2nd opposing flange, 50 Edgewise coil manufacturing apparatus, 51 winding line flange, 51f flange section, 51k winding line section, 53 first facing flange, 54 second facing flange, 55 cylindrical shaft, 56 core shaft,
43 Support shaft, 44 Support arm, 45 Slide part, 46 Braking part, 60 Split stator, 70 Stator, 71 Split core, 71a Back yoke, C coil corner, E coil end part, S coil side part, L1 coil 1 layer First, L2 coil second layer, Lm layer rising part, S1, S2 space, t1-tn first layer turn, u1-un second layer turn.

Claims (7)

A manufacturing apparatus for manufacturing a multi-layered edgewise coil by winding one rectangular wire edgewise.
The flat wire is wound around and rotated around the axis, and the outer peripheral surface has a rectangular cross section.
A first flange having an inner peripheral surface in contact with the outer peripheral surface of the winding wire portion and having a flange having the same width (height) as the width of the flat wire;
A first opposing flange having an inner peripheral surface in contact with an outer peripheral surface of the winding line portion, having a flange having the same width as the flange of the first flange, and positioned to face the first flange;
A second flange having an inner peripheral surface in contact with the outer peripheral surface of the first flange and having a flange having the same width (height) as the width of the rectangular wire;
A second opposing flange having an inner peripheral surface in contact with the outer peripheral surface of the first opposing flange, having a flange having the same width as the flange of the second flange, and positioned so as to face the second flange;
The spacing between the first flange and the first opposing flange can be varied; the spacing between the second flange and the second opposing flange can be varied; and
The first flange and the second flange can be aligned at the same position on the axis, and the first opposed flange and the second opposed flange can be aligned at the same position on the axis. Edgewise coil manufacturing equipment.   The edgewise coil manufacturing apparatus according to claim 1, wherein the first flange is fixed to one end of the winding portion.   The edgewise coil manufacturing apparatus according to claim 1 or 2, wherein the first flange and the second flange are a continuous unit, and an edgewise coil having a two-layer rectangular cross section is manufactured.   An apparatus for manufacturing an edgewise coil having a two-layer rectangular cross section, wherein the winding line portion has an inner peripheral surface that penetrates through a circular composite shaft and contacts an outer peripheral surface of the composite shaft, The composite shaft is composed of a core shaft and a cylindrical shaft that inscribes the core shaft, and has a first threaded portion that is threadedly engaged with the outer peripheral surface of the cylindrical shaft and the inner peripheral surface of the winding line portion, By rotating the cylindrical shaft, the winding portion moves relative to the first opposing flange in the axial direction, and the core shaft and the second opposing flange are screwed together, and the core The shaft line is rotated so that the winding line portion, the first flange, and the first opposing flange move relative to the second opposing flange in the axial direction. 2. An apparatus for manufacturing an edgewise coil according to item 1. A manufacturing apparatus that protrudes in a cylindrical shape from a fixed portion for manufacturing a two-layer rectangular edgewise coil by winding one rectangular wire edgewise.
A second opposing flange protruding from the fixed portion and having an inner peripheral surface of a rectangular cross section;
A composite shaft comprising an axial line aligned with the center of the rectangular cross section of the inner peripheral surface of the second opposing flange, and a core shaft and a cylindrical shaft circumscribing the core shaft at the inner peripheral surface;
A female screw that is freely movable in the axial direction in the cylinder of the second opposing flange, penetrates the composite shaft, and engages with a screw provided on the outer peripheral surface of the cylindrical shaft is provided on the inner peripheral surface. The flange part
A first section having a rectangular cross section, an outer peripheral surface of which is slidably in contact with an inner peripheral surface of the second opposing flange, and an inner peripheral surface of which is slidably in contact with an outer peripheral surface of the flanged portion flange; With an opposing flange,
The composite shaft passes through the cylinder of the second opposing flange, and the core shaft is screwed into a female screw provided in the fixed portion,
The said perforated line part flange has the outer peripheral surface of the rectangular cross section which left | separated the width | variety of the width | variety of the said flat wire between the inner peripheral surface of the rectangular cross section of the said 2nd opposing flange, and is the other side of the said fixing | fixed part. Having a ridge having a width (height) at least twice the width of the flat wire at the tip of
The first opposing flange has a rectangular cross-section in which the distance (thickness) between the inner peripheral surface and the outer peripheral surface is one width of the rectangular wire, and the fixed portion on the opposite side of the winding wire portion flange In the portion on the side, the inner peripheral surface is spaced from the outer peripheral surface of the cylindrical shaft by one width of the flat wire,
A hook for forcibly moving the core shaft by engaging with the end of the cylindrical shaft and the first opposing flange at the boundary between the screw portion screwed with the fixing portion and the screwless screw-free portion. An apparatus for producing edgewise coils, comprising: A method for manufacturing a multi-layered, rectangular edgewise coil by winding one rectangular wire edgewise using the edgewise coil manufacturing apparatus according to any one of claims 1 to 4. And
When winding the turn of the inner circumferential layer, one of the first flange and the first opposing flange is fixed and the other is retracted, while the rectilinear wire already wound edgewise and the retracting flange And whirl around the turn to interrupt the flat wire,
After starting to roll the outer peripheral layer after the predetermined turn has been wound, the first flange and the first opposed flange are fixed, and the front end surface of the retracted flange is fixed. In addition, while fixing one of the second flange and the second opposing flange and retracting the other from the fixed flange, the rectangular wire is first inserted into the gap between the fixed flange and the retracting flange. The edgewise coil of the edgewise coil is characterized in that it is wound so as to be interrupted and then wound so that the rectangular wire of the next turn is interrupted in the gap between the flat wire of the already wound turn and the retreating flange. Production method. A method for manufacturing a two-layer rectangular edgewise coil by winding one rectangular wire edgewise using the edgewise coil manufacturing apparatus according to claim 5, At the start of winding the first layer of the rectangular edgewise coil, the flange portion of the winding wire portion flange has a gap corresponding to one thickness of the flat wire from the tip surface of the second opposing flange. The flat wire is wound one turn so as to interrupt the flat wire into the gap, and then, in the second turn, the core shaft and the cylindrical shaft are rotated so that the wire flange is The flat wire of the first turn is moved backward while making a clearance from the scissors, and the flat wire of the first turn is forcibly slid and shifted on the outer peripheral surface of the flange of the perforated wire portion toward the fixed portion. And the flat angle between The end-wise coil made of the first layer is rotated by rotating the core shaft and the cylindrical shaft after the end of the first layer that has been wound around the intended turn. 2 is accommodated in a cylinder of the opposed flange, and the distance between the distal end surface of the second opposed flange and the flange of the flanged portion flange is made a gap corresponding to the thickness of the flat wire, and the flat angle is formed in the gap. The first turn is turned so as to interrupt the wire, and then the rectangular shaft of the second turn and the first turn of the rectangular wire are turned while the cylindrical shaft is rotated to retract the hook from the fixing portion. 2. A method of manufacturing an edgewise coil, wherein the edgewise coil is inserted between a front end surface of an opposing flange.

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