JP5555933B2 - Winding manufacturing method and manufacturing apparatus - Google Patents

Description

The present invention relates to a manufacturing method and a manufacturing apparatus for manufacturing windings used in electric devices such as rotating devices such as electric motors and generators, and transformers.

In a rotating device such as an electric motor or a generator, a winding is wound around a rotor or a stator, and in an electric device such as a transformer, a winding is used as a primary and secondary coil. . Such a winding is manufactured by winding a wire such as an electric wire around a bobbin or an iron core shaft. As a method of winding the wire around the shaft body, the shaft rotation method that winds the wire around the shaft body while rotating the shaft body and the flyer method that winds the wire rod around the shaft body while fixing the shaft body are put into practical use. Has been.

In the shaft-around method and the flyer method, when the wire is lap-wound, it is created so as to start winding from the inner peripheral side of the winding and to finish winding on the outer peripheral side while sequentially winding on the outer periphery. The created winding requires a space for drawing the wire material at the beginning of winding outward from the inner circumference side. Therefore, in order to eliminate this wasted space and improve the space factor of the winding, A winding method has been proposed. For example, in Patent Document 1, the insulation-coated electric wire having a rectangular cross section is formed as a set of two one-layered windings starting from the inside and the windings connected to each other are used as the basic coil. A winding in which a plurality of wires are stacked is described. Moreover, in patent document 2, after making the intermediate part of the longitudinal direction of a flat conducting wire cross | intersect a teeth part iron core, the coil | winding by winding up to the both ends to the opposite direction to a flat conducting wire was described. Yes. Moreover, in patent document 3, a conducting wire is made to project for a predetermined length, a root is fixed, the projecting part of a conducting wire is bent in a right angle direction with a pressing tool, and it is wound with an alpha winding in a spiral shape so that a space part is formed in the center. It describes the point of manufacturing a coil in which a plurality of spiral bodies are arranged in the horizontal direction.

JP 2004-72824 A JP 2006-109659 A JP 2009-71939 A

In Patent Documents 1 and 2 described above, the winding is configured by arranging a plurality of two layers that are overlapped as a unit. However, since the winding is performed by winding the wire, the spring of the wound wire is performed. A gap is generated between the wires by the action of the back, and the space factor is reduced. Further, when a plurality of unit two layers are arranged, it is necessary to connect the terminal portions of the wire drawn to the outer peripheral side by soldering or the like between adjacent two layers. Therefore, a space for the connection portion is required on the outer peripheral side of the winding. Further, there is a demerit that an insulation process is required due to the presence of the connection portion, and the winding resistance at the connection portion is increased.

In Patent Document 3, since a spiral body is formed by bending a conducting wire, a gap is formed between adjacent turns in the rounded portion formed at the corner of the spiral body, and such a winding is fixed. When used for a child or a rotor, the size of the stator or the rotor is increased, and there is a difficulty in miniaturization. Further, when the conductor is bent, the insulating coating formed on the surface of the conductor at the bent portion or the pressed portion may be damaged, and insulation may not be ensured.

The present invention has been made in view of such problems of the prior art, and an object thereof is to provide a method and an apparatus for manufacturing a winding with a high space factor by using a single continuous wire.

In the winding manufacturing method according to the present invention, the wire is deformed so as to circulate spirally from the outside to the inside by a pushing operation of pressing one wire in the direction intersecting the conveyance direction. A first deformation step in which the curvature of the inner deformation portion is larger than the curvature of the adjacent outer deformation portion, and the outer portion is deformed so as to circulate spirally from the inner side to the outer side by the pushing operation. And a second deformation step of deforming so that the curvature of the deformation portion is smaller than the curvature of the adjacent inner deformation portion, and spirally by alternately performing the first deformation step and the second deformation step. A plurality of wound layers are formed in which the deformed regions of the first deforming step and the second deforming step are spirally overlapped with the deformed wire to bring the wires into close contact with each other. That. Furthermore, the wire has a rectangular cross section. Further, in the first deformation step and the second deformation step, the linear wire is partially deformed into a curved shape to deform the wire so as to circulate spirally.

The winding manufacturing apparatus according to the present invention includes a transport unit that transports one wire in the longitudinal direction, a fulcrum roller disposed on one side of the transport path of the wire, and a push roller disposed on the other side. And moving the push roller in a direction intersecting the conveyance path of the wire and bringing the support roller closer to the downstream side in the conveyance direction of the wire, thereby performing a push-in operation for bending the wire with a desired curvature. Deformation of the deformed part and the deformed part that is curved and deformed by performing the pushing operation while transporting the wire, so that the wire turns around outwardly or inwardly is deformed adjacent to the outside. And a control unit that performs conveyance control of the wire and movement control of the push roller so as to be larger than the portion and smaller than the deformation portion adjacent to the inside. Furthermore, the said deformation | transformation part is provided with the guide member arrange | positioned so that the conveyance path | route of the said wire conveyed while curving and deforming. In addition, a support portion is provided that supports the molded body that is deformed so as to circulate around the wire and is fed out.

According to the present invention, a winding with a high space factor can be manufactured with one continuous wire by having the above-described configuration.

It is a schematic block diagram regarding the manufacturing apparatus of the coil | winding which concerns on this invention. It is a schematic block diagram regarding the modification of the manufacturing apparatus shown in FIG. It is a perspective view regarding a molded object. It is the schematic diagram which looked at the molded object shown in FIG. 3 from the side surface. It is an external appearance perspective view regarding the manufactured coil | winding. It is the front view, side view, and bottom view of a coil | winding. It is explanatory drawing which shows the shape regarding a coil | winding. It is a schematic block diagram which used the coil | winding for rotary equipment.

Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are preferable specific examples for carrying out the present invention, and thus various technical limitations are made. However, the present invention is particularly limited in the following description. Unless otherwise specified, the present invention is not limited to these forms.

FIG. 1 is a schematic configuration diagram relating to a winding manufacturing apparatus according to the present invention. The manufacturing apparatus 1 includes a transport unit 3 that transports the wire 2 in the longitudinal direction, a deforming unit 4 that curves and deforms the wire 2, and a support unit 5 that supports a molded body 20 that deforms the wire 2 in a spiral shape.

The conveyance unit 3 includes a driving roller 10 and a driven roller 11 disposed so as to face the driving roller 10, and rotates the driving roller 10 by sandwiching the wire 2 between the driving roller 10 and the driven roller 11. The wire 2 is fed out from a supply unit (not shown) and conveyed while being shaped so as to be linear in the longitudinal direction.

The deformation unit 4 includes a pressing roller 12, a fulcrum roller 13 disposed opposite to the pressing roller 12, and a pressing roller 14 disposed on the upstream side in the transport direction of the fulcrum roller 13. The fulcrum roller 13 is arranged on one side of the conveyance path of the wire 2, and the pushing roller 12 is arranged on the other side of the conveyance path of the wire 2 and moves in a direction crossing the conveyance path to approach the fulcrum roller 13. It is designed to be separated. Then, the wire 2 is bent and deformed to a desired curvature along the fulcrum roller 13 by a pushing operation in which the pushing roller 12 is moved closer to the downstream side in the transport direction of the fulcrum roller 13 to press the wire 2. When the wire 2 is bent and deformed, the wire 2 can be accurately deformed by holding the wire 2 so that the wire 2 is not bent by the presser roller 14. A guide member 15 is disposed along a path along which the wire 2 is conveyed while being bent and deformed so that the wire 2 is conveyed while being guided by the guide member 15 and circulates in a spiral shape. The molded body 20 is formed by being fed clockwise in the vertical direction.

The support portion 5 includes a support body 16 that extends in a direction perpendicular to the paper surface of FIG. 1, and the support body 16 rotates about a rotation axis that extends in the extending direction. And it sets in the state which inserted the support body 16 inside the molded object 20 extended | stretched so that it may draw | feed out to the orthogonal | vertical direction of the paper surface of FIG. The molded body 20 can be supported in a stable state by rotating the support body 16 together. After the spirally unfolded for a desired number of turns, the winding is manufactured by overlapping the wire 2 in a spiral shape so as to compress the molded body 20 in the unfolding direction as will be described later.

When compressing the molded body 20, a base is disposed at the end of the support 16, and a pair of operating bodies disposed on both sides of the support 16 can be moved along the support 16 toward the base. The winding body can be formed by compressing the molded body 20 by moving the operating body toward the base while the molded body 20 is supported between the operating body and the base. Further, the molded body 20 taken out from the support 16 can be set in another compression device and compressed.

When forming the molded body 20 from the wire 2, a control unit (not shown) performs drive control of the driving roller 10 in the transport unit 3 to control the transport of the wire 2, and performs movement control of the push roller 12 in the deformation unit 4. By rotating the support 16 of the support part 5, the parts are interlocked. Then, as will be described later, the control unit performs a pushing operation of the pushing roller 12 while conveying the wire 2, thereby deforming it so as to spiral around the outside or the inside, and bending the deformed portion of the deformed portion. The shaped body 20 is formed by deforming the wire 2 so that the curvature is larger than the deformed portion adjacent to the outside and smaller than the deformed portion adjacent to the inside.

The wire 2 is made of a conductive material such as copper, which has been used in conventional windings, as a wire, and a coating made of an insulating material such as enamel is formed around it. Note that an insulating tape may be wound around the wire 2 in place of the insulating coating to insulate it. Examples of the shape of the wire 2 include a round wire having a circular cross section and a rectangular wire having a rectangular shape, but other shapes can be used and are not particularly limited. In the present embodiment, a wire having a flat cross-sectional shape is used. Since the cross-sectional shape of a rectangular wire is rectangular, the direction along the short side of the rectangle is referred to as the short side direction when the deformation direction of the wire is indicated, and the direction along the long side of the rectangle is described as the long side direction. . Moreover, the thing of various thickness can also be used about the thickness of the wire 2, and if it is the thickness which can be deform | transformed by press, it can be used as a wire.

The wire 2 conveyed by the conveyance unit 3 is conveyed so as to pass between the pressing roller 12 and the fulcrum roller 13 while being in contact with the pressing roller 14 of the deformation unit 4. The pushing roller 12, the fulcrum roller 13 and the pressing roller 14 are all rotatably supported by a shaft, and the pushing roller 12 is controlled to move toward and away from the fulcrum roller 13 by a moving unit (not shown) and pushed in. I do. When the pushing roller 12 moves close to the downstream side of the fulcrum roller 13 in the conveyance direction of the wire 2 and moves to a position intersecting the conveyance path of the wire 2, the wire 2 passes between the pushing roller 12 and the fulcrum roller 13. At this time, the sheet is forcibly pushed in the pushing direction, and is conveyed while being bent. When the wire 2 is bent and deformed, the wire 2 is pressed by the pressing roller 14 so as not to bend, so that the wire 2 can be accurately deformed.

In addition, since the pushing roller 12 is rotatably supported by the shaft, even if the pushing roller 12 is always in contact with the conveyed wire 2, the pushing roller 12 rotates as the wire 2 is conveyed, and the surface of the wire 2 is damaged. There is no. For this reason, the pressing roller 12 is kept lightly in contact with the linearly transported wire 2 without being separated from the wire 2 even during the pressing operation, and movement control is performed so as to press the wire 2 during the pressing operation. Thus, the response time of the pushing operation can be shortened and the deformation process can be performed efficiently.

The curvature of the wire 2 in the case of bending deformation is set by the conveyance control of the wire 2 in the conveyance unit 3 and the movement control of the push roller 12 in the deformation unit 4. As the moving amount of the pushing roller 12 is increased, the wire 2 is deformed along the peripheral surface of the fulcrum roller 13 to increase its curvature. Therefore, if the diameter of the fulcrum roller 13 is set small to increase the curvature of the peripheral surface, it is possible to deal with a wide range of curvature. Further, the deformation length to be curved and deformed can be set by adjusting the moving amount and moving time of the pressing roller 12 and the conveying amount of the wire 2. For example, curved portions and straight portions can be alternately formed by controlling movement so that the pushing operation of the pushing roller 12 is intermittently performed. Further, if the pushing roller 12 is maintained at a predetermined pushing position, the wire 2 is curved and deformed in a circular shape.

In FIG. 1, the wire 2 is bent and deformed in the short side direction of the cross section, but the pushing roller 12 and the fulcrum roller 13 are brought into contact with the wire 2 from the long side direction of the cross section to bend and deform in the long side direction. It can also be made. Further, the rotation axis of the pressing roller 12 is inclined with respect to the conveying direction of the wire 2, or the circumferential surface of the pressing roller 12 is inclined in a conical shape, so that the short side direction and the long side direction of the cross section of the wire 2 are increased. It is also possible to bend and deform in an oblique direction inclined from either, and the wire 2 can be bent and deformed in an arbitrary direction. Further, the wire 2 can be curved and deformed in an arbitrary direction by inclining the rotation axis of the fulcrum roller 13 with respect to the conveying direction of the wire 2 or by inclining the peripheral surface of the fulcrum roller 13 in a conical surface. . Therefore, instead of the guide member 15, it is also possible to set the rotation shaft and the peripheral surface of the pushing roller 12 or the fulcrum roller 13 as appropriate, and to deform the wire rod 2 so as to spiral around.

Further, as described above, the pressing roller 12, the fulcrum roller 13, and the pressing roller 14 are rotatably supported by the shaft, and therefore do not slide on the surface of the wire 2 when contacting the wire 2. 2 can be curved and deformed without damaging the surface. In particular, in the case where an insulating coating is formed on the peripheral surface of the wire 2, if the insulating coating breaks when it is formed, it is necessary to insulate the wire again after forming the winding. In the apparatus, the insulation of the winding can be reliably ensured by preventing damage to the insulating film.

FIG. 2 is a schematic configuration diagram relating to a modification of the manufacturing apparatus shown in FIG. In this example, a manufacturing apparatus that deforms the wire 2 in two directions is shown. Since the transport unit 3 is the same as that shown in FIG. In the deforming portion 4, the pressing roller 12b, the fulcrum roller 13a, and the pressing roller 14b are arranged on one side of the conveying path of the wire 2, and the pressing roller 12a, the fulcrum roller 13b, and the pressing roller 14a are arranged on the other side. . The guide member 15 is not shown in the figure, but it is commonly used when the guide member 15 is spirally deformed in two directions, or is slid to the respective setting positions when being deformed spirally in each direction. It can also be installed in two directions.

The pressing roller 12a, the fulcrum roller 13a, and the pressing roller 14a are formed so that the wire 2 is curved and deformed in one direction (downward in the figure) and the wire 2 is drawn out in a clockwise direction like FIG. On the other hand, the pressing roller 12b, the fulcrum roller 13b, and the pressing roller 14b are formed so that the wire 2 is curved and deformed in the opposite direction (upward in the drawing), and the wire 2 is spirally fed out counterclockwise.

As described above, since the winding direction in which the wire 2 is deformed in a spiral shape can be changed as appropriate, when forming a plurality of coils with a single continuous wire as described later, from either of both ends of the coil. However, it becomes possible to form, and it can be formed so that the connecting wire is shortened according to the arrangement of the coils.

FIG. 3 is a perspective view of the molded body 20. The formed body 20 is formed so as to extend in the development direction TT so as to circulate in a spiral shape, and in this example, one continuous wire 2 is curved in a right-angle direction that constitutes each circulatory part. By repeatedly forming the curved portion 20a which is the deformed portion, the straight portion 20b corresponding to the long side portion, the curved portion 20a curved in the right-angle direction, the straight portion 20c corresponding to the short side portion, and the like, It can form so that it may wrap around. The curved portion 20a, which is a deformed portion, is curved so that the curvature of the curved portion corresponding to the inner circumferential portion is larger than the curvature of the curved portion corresponding to the adjacent outer circumferential portion.

FIG. 4 is a schematic view of the molded body 20 shown in FIG. 3 as viewed from the side. The straight portion 20b is drawn in a zigzag broken line shape in the development direction TT of the molded body 20, and the bent portions on both sides correspond to the curved portion 20a and the straight portion 20c. The molded body 20 is helically deformed by repeating two continuous deformation regions F1 and F2. The deformation region F1 is deformed so as to circulate spirally from the outside toward the inside, and corresponds to a winding layer portion 30 of a winding described later. And in the deformation | transformation area | region F1, it curves and forms so that the curvature of the curve part 20a which is a deformation | transformation part may become large as it goes inside. Further, the deformation area F2 following the deformation area F1 is deformed so as to spiral around from the inside to the outside, and corresponds to a winding layer portion 31 of a winding described later. And in the deformation | transformation area | region F2, it curves and forms so that the curvature of the curve part 20a which is a deformation | transformation part may become small as it goes outside.

And in the part which transfers to the deformation | transformation area | region F2 from the deformation | transformation area | region F1, the deformation | transformation location f2 on the deformation | transformation area | region F1 side is formed so that a linear part and a curve part may overlap inside, but the deformation | transformation location f3 on the deformation | transformation area | region F2 side Since it is formed in the same shape so as to abut against the deformed portion f <b> 1 of the deformation region F <b> 1, the wound layer portion 31 can be formed adjacent to the wound layer portion 30. Moreover, in the part which transfers to the deformation | transformation area | region F1 from the deformation | transformation area | region F2, the deformation | transformation location f5 by the side of the deformation | transformation area F2 is formed so that it may overlap outside, but the deformation | transformation location f6 by the side of the deformation | transformation area | region F1 is a deformation | transformation location of the deformation | transformation area F2. Since it is formed in a shape that abuts against f4, the wound layer portion 30 can be formed adjacent to the wound layer portion 31.

In addition, the deformation regions F1 and F2 can independently increase or decrease the number of turns, so that the number of turns of each wound layer portion can be set as appropriate. For example, the number of turns of the wound layer portion can be increased sequentially, or the number of turns can be increased only for some of the wound layer portions. In addition, if the circumferential length of all the winding layer portions is set to be the same except for the connecting portion on the inner circumferential side, the winding can be easily inserted into a support body such as a tooth and is supported in a stable state. Become so.

In this embodiment, in order to form a curved portion that is curved and deformed in a perpendicular direction, the curvature of the curved portion is adjusted by adjusting the amount of movement of the push roller 12 and the conveyance amount of the wire 2 as shown in FIG. It can shape | mold into the molded object 20 expand | deployed so that it may wrap around spirally. First, the first deformation process corresponding to the deformation area F1 is performed. After conveying the wire 2 by the length of the long side portion corresponding to the outermost peripheral side, the wire 2 is pressed by the pushing operation of the pushing roller 12 in the direction intersecting the conveying direction while conveying the wire 2 to shorten the cross section. A curved portion having a predetermined curvature is formed by bending in the side direction. Subsequently, after the wire 2 is conveyed by the length of the short side portion, a curved portion having a predetermined curvature is formed by the pushing operation of the pushing roller 12. In this way, while continuously transporting the wire 2, the deformation process for forming the long side portion-curved portion-short side portion-curved portion is repeatedly performed to deform the wire 2 so as to circulate spirally from the outside to the inside. At the same time, the deformation is performed such that the curvature of the inner curved portion is larger than the curvature of the adjacent outer curved portion, thereby forming the deformation region F1.

After the deformation region F1 is formed, the sheet is subsequently conveyed by a length corresponding to the connecting portion, and then a curved portion is formed by the pressing operation by the pressing roller 12, and the second deformation process corresponding to the deformation region F2 is performed. After the wire 2 is conveyed by the length of the long side portion corresponding to the innermost peripheral side, a curved portion having a predetermined curvature is formed by the pushing operation of the pushing roller 12. Subsequently, after the wire 2 is conveyed by the length of the short side portion, a curved portion having a predetermined curvature is formed by the pushing operation of the pushing roller 12. While carrying the wire 2 in this manner, the deformation process of forming the long side portion-curved portion-short side portion-curved portion is repeated to deform the wire 2 so as to circulate spirally from the inside to the outside. The deformed region F2 is formed by deforming so that the curvature of the outer curved portion is smaller than the curvature of the adjacent inner curved portion. After the deformation region F1 is formed, the sheet is subsequently conveyed by a length corresponding to the connecting portion, and then the curved portion is formed by the pushing operation of the pushing roller 12.

In this way, the wire 1 can be deformed in a helical shape by alternately performing the first deformation process and the second deformation process described above while continuously conveying the wire 2, and the molding can be performed efficiently. And each deformation | transformation area | region by a 1st deformation | transformation process and a 2nd deformation | transformation process is piled up spirally with respect to the shape | molded wire 2, and wires are closely_contact | adhered and a some winding layer part is formed, and between winding layer parts The windings are manufactured by arranging them closely.

FIG. 5 is an external perspective view of the manufactured winding. FIG. 6 is a front view (FIG. 6A), a side view (FIG. 6B), and a bottom view (FIG. 6C) of the winding. )). Moreover, FIG.6 (d) is a front view regarding the winding layer part 31 among windings. The winding C is formed by alternately arranging winding layers 30 and 31 in which a single continuous wire 2 deformed so as to circulate in a spiral shape is partially spirally adhered in the thickness direction. Configured. In this example, a space is formed in the winding C, and in the case of a rotating device, the winding C is inserted into a support such as a tooth. In the case of a transformer, it is inserted into an iron core. The winding layer portions 30 and 31 are formed by superimposing and sticking the wire 2 in a spiral shape, and adjacent winding layer portions are continuously connected by the wire 2 on the inner peripheral side or the outer peripheral side. Yes. And the edge part of the wire 2 is arrange | positioned at the outer peripheral side or inner peripheral side of the winding layer part of both ends. Here, the thickness direction of the wound layer portion is a direction perpendicular to the laminated surface in contact with both sides of the wire 2 stacked in a spiral shape, and in this example, is the long side direction of the cross section of the wire 2 having a rectangular cross section. 3 is a development direction TT of the molded body 20 shown in FIG.

As shown in FIGS. 6 (a) and 6 (d), the wound layers 30 and 31 are deformed so that the wire 2 having a rectangular cross section is bent at right angles to the short side direction of the cross section and overlapped in a spiral shape. It is configured together. Here, the “spiral shape” means a state in which a single wire 2 is laminated so as to overlap while rotating. On the other hand, the term “spiral” refers to a state in which one wire 2 is displaced in the developing direction without being laminated while rotating, as in the molded body 20 shown in FIG. 3. In this example, the wire 2 is curved in the short-side direction of the cross section, but the wound layer portion can also be configured by curving the wire 2 in the long-side direction of the cross-section and superimposing them in a spiral shape.

In this example, the winding layer portions 30 and 31 are composed of four rounded portions, and each rounded portion bends and deforms the wire 2 in a right angle direction at four locations, and is a corner portion when viewed from the thickness direction of the winding layer portions 30 and 31. Is formed in a rounded rectangular shape. As for the wound layer portion 30, four corners of each of the surrounding portions are formed in a curved portion 30a having a predetermined curvature, the four sides are formed in a straight line, and one pair of opposing sides is formed. The long side portion 30b having a long length and the other pair are a short side portion 30c having a short length. The curved portion 30a is overlapped with the curved portion 20a shown in FIG. 3, and the long side portion 30b and the short side portion 30c are overlapped with the straight portions 20b and 20c shown in FIG. 3, respectively. Similarly to the wound layer portion 30, the wound layer portion 31 is composed of a curved portion 31a, a long side portion 31b, and a short side portion 31c, and the curved portion 20a and the straight portions 20b and 20c are overlapped with each other. Then, the curved portion 30a that is a corner is formed so that the curvature decreases sequentially from the inner circumferential side to the outer circumferential side, and the wire 2 is overlapped so as to be in close contact with the entire circumference. ing. In order to bring the adjacent wire portions 2 of the surrounding portions into close contact with each other, the curvature radius corresponding to the curvature of the curved portion of the surrounding portion adjacent to the outer peripheral side is set to the curvature corresponding to the curvature of the curved portion of the peripheral portion adjacent to the inner peripheral side. If the radius is set to a value obtained by adding the length of the cross section of the wire 2 in the short side direction, the curved portions can be formed in close contact with each other. The curved portion 31a is also formed so that the curvature of the wire 2 is set in the same manner as the curved portion 30a, and the curvature gradually increases from the outer peripheral portion toward the inner peripheral portion. It is piled up so that it may closely adhere to the circumference.

As shown in FIG. 6B, the winding C is configured by alternately arranging the winding layer portions 30 and 31. The winding layer portion 30 spirally overlaps the wire 2 from the outer peripheral side to the inner peripheral side, and the wire 2 is continuously transferred from the inner peripheral side to the winding layer portion 31 at the connecting portion 30d. The wire 2 is spirally overlapped from the peripheral side to the outer peripheral side, and the wire 2 is continued from the outer peripheral side at the connecting portion 31e to move to the next wound layer portion 30.

The wound layer portion 30 and the wound layer portion 31 are in contact with each other so that the long side portion 30b and the short side portion 30c abut each other at the side ends, and the mutual wire 2 does not enter and is in a stable state. Closely arranged. Further, in the wound layer portion 30 and the wound layer portion 31, the curved portions 30a at both ends of the short side portion 30c (upper side in FIGS. 6A and 6D) where the connecting portions are not arranged are formed in the same shape. In close contact with each other, they are in close contact with each other. On the other hand, the curvilinear portion 30a at both ends of the short side portion 30c (the lower side in FIGS. 6A and 6D) where the connecting portion is disposed is connected to the inner peripheral side of the wound layer portion 30d. Is arranged so that the winding layer portion 31 and the curved portion are shifted from each other, but the short side portions 30c are in contact with each other so that the mutual wire enters. It is closely arranged in a stable state.

In this example, the winding layers 30 and 31 are set to the same number of turns. However, since the number of turns can be set for each, the number of turns can be increased or decreased with respect to the adjacent winding layers. It becomes possible. And when increasing / decreasing the number of turns, if the increase / decrease amount of the number of turns is arranged on the outer peripheral side or the inner peripheral side, the adjacent wound layer parts come into contact with each other so as to abut against each other at the intermediate part It is possible to maintain the closely contacted state, and it is possible to obtain a winding in which the wound layer portion is closely contacted and disposed.

In this way, the wire rods of the respective winding layer portions can be disposed in close contact with each other in a spiral shape, and can also be disposed in close contact between the winding layer portions, so that the space factor of the winding can be improved. In addition, by arranging the connecting portions on one short side portion on the inner peripheral side and the outer peripheral side, each winding layer portion is formed by one continuous wire without affecting the close contact arrangement of the long side portion and the short side portion. Can be linked.

FIG. 7 is an explanatory diagram showing a shape related to the winding. In the above-described example, the rectangular winding has been described. However, it may be formed in a cylindrical shape as shown in FIG. 7A, or may be formed in an elliptical cylindrical shape. In the example shown in FIG. 7A, the wire is deformed in a curved shape over the entire circumference, and the whole is a deformed portion. And the curvature of a deformation | transformation part is set larger than the deformation part adjacent to an outer side and smaller than the deformation part adjacent to an inner side, and it forms so that a deformation | transformation part closely_contact | adheres.

Moreover, as shown in FIG.7 (b), it can also form in the cylinder shape of a triangle, and can also form in the shape of various polygonal cylinders. Moreover, as shown in FIG.7 (c), it can also be easily formed in the shape which combined the curve part and the linear part corresponding to the attachment position. In the example shown in FIGS. 7B and 7C, the curved portion is a deformed portion, and the deformed portion is partially arranged. Also in this example, the curvature of the deformed portion is set larger than the deformed portion adjacent to the outside and smaller than the deformed portion adjacent to the inside, and the deformed portions are formed in close contact with each other.

In addition to the example shown in FIG. 7, the wire 2 can be curved and deformed to form deformed portions of various shapes, and the curvature of the deformed portion is set so as to be in close contact with and overlap with the deformed portion adjacent to the outside or inside. A winding with a high space factor that is appropriately formed according to the mounting location can be obtained.

FIG. 8 is a schematic configuration diagram in which a winding is used in a rotating device. In this example, a plurality of coils 200 made of windings are attached to the stator of the rotating device. The coils 200 are respectively inserted into a plurality of teeth 202 provided on the inner peripheral side of the stator yoke 201 and are arranged in the circumferential direction. In FIG. 8, the coil 200 is shown in a sectional view, and the wire constituting the coil 200 is drawn in a rectangular section. The coil 200 constitutes a three-phase coil, and every two in-phase coils 200 are arranged and connected to each other.

A plurality of winding layer portions constituting the coil 200 are arranged in the radial direction of the stator, and the number of turns of the winding layer portion from the inner diameter side toward the outer diameter side corresponding to the shape of the slot between the teeth 202. Is set to increase. Since the number of turns can be changed for each winding layer part of the manufactured winding, if the number of turns of the winding layer part is set according to the shape of the slot, the wire is arranged with as little gap as possible in the slot Thus, the space factor can be improved. In this example, the wire rods are arranged in such a manner that there is as little gap as possible in the slot by making the number of turns of the adjacent winding layers of the coil 200 different. It should be noted that the number of winding layers constituting the coil 200 can be appropriately set according to the design of the stator, and the number of winding layers of some of the coils 200 can be varied.

In this example, the coil 200 uses the winding shown in FIG. 6, and the long side portion of the winding is disposed in the slot and the short side portion of the winding is disposed so as to protrude above and below the teeth. The Since the curved portions on both sides of the short side portion of the winding are set to have a small curvature, a space is created between the adjacent curved portions between the adjacent coils 20, and the connecting wire and the lead-out It can be used as a space for arranging lines. Therefore, it is possible to make the entire stator more compact than in the case where a crossover or the like is arranged on the upper surface of the short side portion as in the conventional coil.

Further, as described above, since the connecting portion of the winding layer portion of the winding is disposed in close contact with the inner peripheral side and the outer peripheral side of one short side portion, the long side portion of the coil is inserted into the slot. If it attaches in this way, the density of the wire in a slot can be improved, and it becomes possible to achieve compactness by reducing the thickness of the short side part which protrudes up and down of teeth.

Further, as described above, the coil can be manufactured by changing the winding direction with one wire, so that the wire is deformed in one winding direction from the inner diameter side to the outer diameter side for one coil. In this case, the next coil can be formed from the outer diameter side toward the inner diameter side by deforming the wire in the same or opposite circulation direction with respect to the next coil. Therefore, it is possible to set adjacent coils so as to be in the same or opposite winding directions and to connect each other with a continuous wire as a jumper on the outer diameter side. Therefore, it is not necessary to attach and connect a crossover wire separately from the wire, and a plurality of coils can be manufactured collectively in a state where they are connected by the crossover wire. In addition, by connecting on the outer diameter side of adjacent coils, it is possible to shorten the length of the wire used as a jumper wire compared to the case of connecting from the inner diameter side of one coil to the outer diameter side of the other coil. It becomes.

In the example described above, the manufactured winding is inserted as a coil inside the stator and the rotor is attached to the inside of the coil to configure the rotating device. However, the manufactured winding is outside the stator. The rotating device can be configured to be inserted as a coil and have a rotor attached to the outside of the coil. In addition, the rotating device can be configured by inserting the manufactured winding into the rotor.

Moreover, it is possible to use the manufactured coil | winding besides the rotary apparatus which has a stator mentioned above, It does not specifically limit. For example, the present invention can also be applied to a driving device such as a linear motor in which a plurality of coils are linearly arranged. The transformer can be applied to the input side coil and the output side coil. In that case, the number of winding layers of the input side coil and the output side coil is set to different numbers, or the number of turns of the winding layer portions is different. Can be set to Further, it is possible to easily attach a plurality of windings as the output side coil, and it is possible to cope with various designs of the transformer.

C: Winding, 1 ... Manufacturing device, 2 ... Wire rod, 3 ... Conveying unit, 4 ... Deformation unit, 5 ... Supporting unit, 10 ... Drive roller, 11. ..Drive roller, 12 ... Push roller, 13 ... Supporting roller, 14 ... Presser roller, 15 ... Guide member, 16 ... Support, 20 ... Molded body, 30 ... -Winding layer part, 31 ... Winding layer part, 200 ... Coil, 201 ... Yoke, 202 ... Teeth

Claims (2)

A single rectangular shaped cross-section straight wire, while continuously conveying to pass between pressing roller and the fulcrum roller while contacting the pressing roller by the pressing roller close to and away from relative to said fulcrum roller The pushing operation of pressing in the direction crossing the conveying direction causes the wire to be deformed so as to circulate spirally from the outside to the inside by partially deforming into a curved shape, and the curvature of the inside deformed portion is adjacent. A first deformation step for deforming to be larger than the curvature of the outer deformed portion that fits, and the wire rod being deformed partially from the inside to the outside by the pushing operation while being continuously conveyed. A second deformation step of deforming so as to circulate in a spiral toward the outer side and deforming so that the curvature of the outer deformation portion is smaller than the curvature of the adjacent inner deformation portion; Each of the deformation regions of the first deformation step and the second deformation step is spirally stacked on the wire deformed in a spiral shape by alternately performing the first deformation step and the second deformation step. The manufacturing method of the coil | winding which forms the several winding layer part which united together the said wire materials over the perimeter together. A conveyance unit that conveys a linear wire having a flat rectangular cross section in the longitudinal direction, a fulcrum roller disposed on one side of the conveyance path of the wire, and a fulcrum roller that is disposed on the other side and close to the fulcrum roller -It has a pressing roller and a pressing roller that are spaced apart from each other, and moves the pressing roller in a direction intersecting the conveyance path of the wire to bring the fulcrum roller closer to the downstream side in the conveyance direction of the wire, thereby making the wire have a desired curvature A deforming portion that performs a pushing operation to bend and deform, and a deformed portion that is deformed so as to be spirally circulated outward or inward by performing the pushing operation while conveying the wire. The wire rod conveyance control and the push roller movement control are set so that the curvature of the wire is larger than the deformation portion adjacent to the outside and smaller than the deformation portion adjacent to the inside. And a control unit that performs, and a support portion for supporting the shaped body drawn out deformed so as to circulate the wire helically, wherein the deformable portion is conveyed in the wire which is conveyed while being the bending deformation A winding manufacturing apparatus comprising a guide member arranged along a path .