JP6272511B2 - Coil device and manufacturing method thereof - Google Patents

Description

  The present invention relates to a coil device used for, for example, a generator, an electric motor, or a resolver, and a manufacturing method thereof.

  In a conventional resolver coil device, terminal pins are respectively inserted into a plurality of elongated holes provided in a coil end connection portion. The elongated hole is provided with a constricted portion and a round hole portion. After winding the conducting wire of the coil terminal around the terminal pin, the terminal pin is moved to the inside of the stator and fixed to the round hole. Thereby, slack is formed in the conducting wire of a coil terminal (for example, refer to patent documents 1).

  In another conventional resolver coil device, after the jig pin is inserted into the terminal pin holding portion, the terminal conductor is brought into contact with the jig pin and fixed to the terminal pin so that the terminal conductor is tensioned. Thereafter, the jig pins are removed to form a slack in the conducting wire (see, for example, Patent Document 2).

JP 2004-56903 A JP 2009-268230 A

  In the conventional resolver coil device disclosed in Patent Document 1, a process for moving and fixing the terminal pins to the inside of the stator is necessary. Also, since it is necessary to move the terminal pin to the round hole along the shape of the long hole manufactured in advance, it is necessary to take a large amount of slack, and it is difficult to adjust the amount of slack, Rewinding of the conductive wire in the coil or dropping of the conductive wire at the terminal pin was likely to occur. Furthermore, since the slack direction of the conducting wire varies in the circumferential direction and the axial direction of the stator, it is difficult to form a stable slack, and the risk of disconnection of the conducting wire of the coil terminal cannot be reduced.

  Further, in the conventional resolver coil device disclosed in Patent Document 2, since it is necessary to bring the conducting wire into direct contact with the jig pin, the conducting wire may rub against the jig pin, which may cause damage or breakage of the insulating film. It was.

  This invention is made in order to solve the above subjects, and it aims at obtaining the coil apparatus which can form a slack in the terminal conducting wire part of a coil group stably and easily, and its manufacturing method. To do.

The coil device according to the present invention includes an iron core having a plurality of teeth portions, a plurality of winding portions provided in the teeth portions, and a plurality of terminal conducting wire portions drawn from the winding portions. And a coil end connection portion provided with a plurality of terminals to which the terminal conducting wire portion is connected, the coil end connection portion being fixed to the iron core and provided with a terminal. And a movable guide portion that is connected to the connection portion main body via an elastic deformation portion and that is hung on the terminal conductor portion and guides the terminal conductor portion to the terminal.
Moreover, the manufacturing method of the coil device according to the present invention includes an iron core having a plurality of teeth portions, a plurality of winding portions provided in the teeth portions, and a plurality of terminal conductors drawn from the winding portions. And a coil end connecting portion provided with a plurality of terminals to which the terminal conducting wire portion is connected, the coil end connecting portion being provided with the coil end connecting portion. An elastic deformation step of displacing the movable guide portion connected to the elastic deformation portion by elastically deforming the elastic deformation portion, and a connection for connecting the terminal lead wire portion to the terminal by hanging the terminal lead wire portion on the movable guide portion And a restoration step of forming a slack in the terminal conductor portion by restoring the elastic deformation portion and returning the movable guide portion.

  In the coil device and the manufacturing method thereof according to the present invention, the elastically deforming portion is elastically deformed, the terminal conducting wire portion is connected to the terminal, and the elastic deforming portion is restored so that the terminal conducting wire portion of the coil group is loosened stably and easily. Can be formed.

It is a perspective view which shows the stator by Embodiment 1 of this invention. It is a front view which shows the stator of FIG. It is a perspective view which shows the state which cut | disconnected the coil end connection part of FIG. 1 along the III-III line. It is a perspective view which shows the state which cut | disconnected the stator of FIG. 1 along the IV-IV line. It is sectional drawing which follows the VV line of FIG. It is a perspective view which shows the state before mounting | wearing with a coil group to the iron core of FIG. It is sectional drawing which shows the state before mounting | wearing a coil group with the iron core of FIG. It is a perspective view which shows the state which elastically deformed the elastic deformation part of FIG. It is sectional drawing which shows the state which elastically deformed the elastic deformation part of FIG. It is a perspective view which shows the state which mounted | wore the coil group with the iron core of FIG. It is sectional drawing which shows the state which mounted | wore the coil group with the iron core of FIG. It is a perspective view which shows the state which removed the jig | tool from the stator of FIG. It is sectional drawing which shows the state which removed the jig | tool from the stator of FIG. It is explanatory drawing which shows the principal part of FIG. 11 typically. It is a perspective view which shows the part corresponded in FIG. 3 of the stator by Embodiment 2 of this invention. FIG. 6 is a perspective view showing a portion corresponding to FIG. 4 of the stator according to the second embodiment. FIG. 6 is a cross-sectional view of a portion corresponding to FIG. 5 of the stator according to the second embodiment. It is explanatory drawing which modeled the principal part of FIG. 10, and was shown from the front.

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings, taking a stator used in a resolver as an example.
Embodiment 1 FIG.
1 is a perspective view showing a stator according to Embodiment 1 of the present invention, and FIG. 2 is a front view showing the stator of FIG. In the figure, the stator 1 has an annular iron core 2, an insulator 3 fixed to the iron core 2, and a coil group 4.

  A plurality of teeth portions 2 a protruding inward in the radial direction are provided on the inner peripheral portion of the iron core 2. The teeth part 2a is arrange | positioned at intervals in the circumferential direction of the iron core 2. As shown in FIG. Thereby, the slot part 2b is formed between the mutually adjacent teeth parts 2a. That is, the teeth portions 2 a and the slot portions 2 b are alternately arranged in the circumferential direction of the iron core 2.

  The coil group 4 has a plurality of winding portions 4a formed by winding a conductive wire around the tooth portion 2a, and a plurality of terminal conducting wire portions 4b drawn from the winding portion 4a.

  The insulator 3 includes a winding mounting portion 3 a that covers the periphery of the tooth portion 2 a of the iron core 2, and a coil end connection portion 3 b that protrudes radially outward from a part in the circumferential direction of the iron core 2.

  A plurality of (six in this example) terminal pins 5 as terminals are fixed to the coil end connection portion 3b. An intermediate portion of each terminal pin 5 is embedded in the coil end connection portion 3b. Further, the first end portion of each terminal pin 5 protrudes from the coil end connection portion 3 b to one side in the axial direction of the iron core 2. A second end portion of each terminal pin 5 protrudes outward in the radial direction of the iron core 2 from the coil end connection portion 3b. A corresponding terminal conductor 4 b is connected to the first end of each terminal pin 5.

  3 is a perspective view showing a state where the coil end connection portion 3b of FIG. 1 is cut along the line III-III, and FIG. 4 is a perspective view showing a state where the stator 1 of FIG. 1 is cut along the line IV-IV. FIG. 5 and FIG. 5 are cross-sectional views taken along the line VV in FIG.

  The coil end connection portion 3b includes a connection portion main body 3c, a plurality of (in this example, two) elastic deformation portions 3d, and a plurality of (in this example, three) movable guides. It has a portion 3e, a connecting portion 3f, and a plurality (three in this example) of fixed guide portions (stationary portions) 3g.

  The connection portion main body 3 c is fixed to the iron core 2. Moreover, all the terminal pins 5 are provided in the connection part main body 3c.

  The coil end connecting portion 3b is provided with a through hole 7 having a rectangular cross section. The through hole 7 passes through the coil end connection portion 3 b in parallel with the axial direction of the iron core 2. The connection portion main body 3 c is disposed on the opposite side to the iron core 2 with respect to the through hole 7.

  The terminal conducting wire portion 4 b is disposed on the first end surface of the coil end connection portion 3 b in the axial direction of the iron core 2 (the surface from which the first end portion of the terminal pin 5 protrudes). 1 crosses over the opening on the end face side.

  The elastic deformation portion 3d is disposed in the opening of the coil end connection portion 3b. The elastic deformation portion 3d is a spring portion made of an elastic member, and functions as a leaf spring that can be elastically deformed in the radial direction of the iron core 2. The first end of the elastically deforming portion 3 d is fixed to the inner wall surface of the through hole 7. The second end portion of the elastic deformation portion 3d is connected to the connecting portion 3f.

  The movable guide part 3e is connected to the connecting part 3f. That is, the movable guide portion 3e is connected to the connection portion main body 3c via the elastic deformation portion 3d, and the connecting portion 3f is interposed between the movable guide portion 3e and the elastic deformation portion 3d. The connecting portion 3f functions as a base that supports the movable guide portion 3e.

  The movable guide portion 3 e protrudes from the opening on the first end face side of the through hole 7 to one side in the axial direction of the iron core 2. In addition, the movable guide portion 3 e is disposed between the terminal pin 5 and the iron core 2. A terminal conductor 4b is hung on the movable guide 3e. Thereby, the movable guide part 3e is guiding the terminal conducting wire part 4b to the corresponding terminal pin 5. FIG.

  The movable guide portion 3e can be displaced in a direction (in the radial direction of the iron core 2) in which the reaction force generated by the tension of the terminal conducting wire portion 4b is increased or decreased by deformation and restoration of the elastic deformation portion 3d. That is, the movable guide part 3e can be displaced in a direction approaching the iron core 2 by elastic deformation of the elastic deformation part 3d.

  The dimension (width dimension) of each elastic deformation part 3d and each movable guide part 3e in the circumferential direction of the iron core 2 (the width direction of the coil end connection part 3b (left and right direction in FIG. 2)) is the connecting part 3f in the same direction. It is smaller than the dimension (width dimension). In the circumferential direction of the iron core 2, the movable guide portions 3e and the elastic deformation portions 3d are alternately arranged. That is, with respect to the circumferential direction of the iron core 2, the elastic deformation portion 3d is disposed between the adjacent movable guide portions 3e.

  The fixed guide portion 3g is provided in the connection portion main body 3c. The fixed guide portion 3g is provided at the edge of the through hole 7 on the terminal pin 5 side. Further, each fixed guide portion 3g protrudes from the first end face of the coil end connection portion 3b to the one side in the axial direction of the iron core 2, and faces the corresponding movable guide portion 3e.

  Next, the manufacturing method of the stator 1, especially the connection method to the terminal pin 5 of the terminal conducting wire part 4b is demonstrated. The manufacturing method of the stator 1 in the first embodiment includes an elastic deformation step in which the elastic deformation portion 3d is deformed to displace the movable guide portion 3e in a direction approaching the iron core 2 (inward in the radial direction of the iron core 2), and the movable guide portion. A connecting step of connecting the terminal conductor 4b to the terminal pin 5 by hooking the terminal conductor 4b on 3e, and a direction in which the elastically deforming portion 3d is restored to move the movable guide 3e away from the iron core 2 (outside in the radial direction of the iron core 2) And a restoration process.

  6 is a perspective view showing a state before the coil group 4 is attached to the iron core 2 of FIG. 4, FIG. 7 is a cross-sectional view showing a state before the coil group 4 is attached to the iron core 2 of FIG. 5, and FIG. FIG. 9 is a cross-sectional view showing a state in which the elastic deformation portion 3d in FIG. 7 is elastically deformed.

  In the elastic deformation step, a jig 6 is prepared for expanding the gap between the connecting portion 3f and the inner wall surface of the through hole 7 to elastically deform the elastic deformation portion 3d. The jig 6 is provided with a plurality of pin portions 6a. The thickness (diameter) of the pin portion 6 a is larger than the gap size between the connecting portion 3 f and the inner wall surface of the through hole 7.

  By providing the through hole 7 in the coil end connection portion 3b, the pin portion 6a can be inserted between the connecting portion 3f and the connection portion main body 3c from the elastic deformation portion 3d side. In the elastic deformation step, the pin portion 6 a is inserted between the connecting portion 3 f and the inner wall surface of the through hole 7 to elastically deform the elastic deformation portion 3 d and move the movable guide portion 3 e closer to the iron core 2. Displace.

  10 is a perspective view showing a state where the coil group 4 is mounted on the iron core 2 of FIG. 8, and FIG. 11 is a cross-sectional view showing a state where the coil group 4 is mounted on the iron core 2 of FIG. In the connecting step, after the winding portion 4a is mounted on the corresponding tooth portion 2a, the terminal conducting wire portion 4b is connected to the corresponding terminal pin 5, that is, wound and fixed. At this time, the terminal conducting wire portion 4b is hung on the movable guide portion 3e in a state where a tension matching the specification of the conducting wire is applied.

  12 is a perspective view showing a state where the jig 6 is removed from the stator 1 of FIG. 10, and FIG. 13 is a cross-sectional view showing a state where the jig 6 is removed from the stator 1 of FIG. In the restoration step, the pin portion 6a is pulled out from the coil end connection portion 3b, and the jig 6 is removed from the stator 1. Thereby, the elastic deformation portion 3d is restored, and the movable guide portion 3e returns to the direction away from the iron core 2 (the direction in which the reaction force generated by the tension of the terminal conducting wire portion 4b is reduced).

In such a stator 1, the elastically deforming portion 3 d is elastically deformed to connect the terminal conductor portion 4 b to the terminal pin 5, and the elastically deforming portion 3 d is restored, so that the terminal conductor portion 4 b is loosened stably and easily. Can be formed.
Moreover, since the terminal conducting wire portion 4b does not directly contact the pin portion 6a of the jig 6, the terminal conducting wire portion 4b does not rub against the pin portion 6a, and damage to the insulating film and disconnection of the terminal conducting wire portion 4b can be prevented.

Moreover, the amount of slackness of the terminal conducting wire portion 4b can be easily adjusted by adjusting the deformation amount of the elastic deformation portion 3d.
Furthermore, since the slack direction of the terminal conducting wire portion 4b is more reliably the outer direction of the movable guide portion 3e, the posture of the terminal conducting wire portion 4b is stabilized, and the risk of disconnection of the terminal conducting wire portion 4b can be reduced.

  Furthermore, since the pin portion 6a is inserted between the connecting portion 3f and the connection portion main body 3c to elastically deform the elastic deformation portion 3d, the displacement of the movable guide portion 3e is changed by changing the thickness of the pin portion 6a. The amount can be easily fine tuned. Thereby, the amount of slackness of the terminal conductor 4b can be adjusted to prevent the terminal conductor 4b from unwinding and falling off.

  Further, the mounting direction of the jig 6 (the insertion direction of the pin portion 6a) is the direction in which the iron core 2 is attached to a winding machine (not shown) for the winding process of the coil group 4 (the axial direction of the iron core 2). Since they are the same, by providing the jig 6 in the winding machine in advance, it is possible to simultaneously perform the process of attaching the iron core 2 to the winding machine for the winding process and the elastic deformation process. .

  Further, FIG. 14 is an explanatory diagram schematically showing the main part of FIG. The movable guide part 3e is displaced so as to become an obtuse angle with respect to the direction of reducing the reaction force received from the tension of the terminal conductor part 4b that comes into contact. For this reason, at the time of winding, a force acting in the root direction of the movable guide part 3e is generated in the terminal conductor part 4b by the tension of the terminal conductor part 4b, and the terminal conductor part 4b is prevented from dropping from the movable guide part 3e. be able to.

  Furthermore, since the fixed guide portion 3g is provided in the coil end connection portion 3b, it is possible to prevent the pin portion 6a of the jig 6 from being exposed and to protect the terminal conductor portion 4b. Further, the terminal conductor 4b is wrapped around the movable guide portion 3e and the fixed guide portion 3g for one turn (a different manner from the first embodiment), so that slack can be more reliably formed.

Embodiment 2. FIG.
15 is a perspective view showing a portion corresponding to FIG. 3 of the stator according to the second embodiment of the present invention, and FIG. 16 is a perspective view showing a portion corresponding to FIG. 4 of the stator according to the second embodiment. FIG. 17 is a cross-sectional view of a portion corresponding to FIG. 5 of the stator according to the second embodiment.

  Although the L-shaped elastic deformation portion 3d is shown in the first embodiment, the U-shaped elastic deformation portion 3h is used in the second embodiment. Other configurations are the same as those in the first embodiment.

According to such a configuration, the length of the elastic deformation portion 3h can be extended as compared with the first embodiment, and the movable guide portion 3e can be flexibly supported. For this reason, the displacement amount of the movable guide part 3e can be expanded.
Further, it is not necessary to configure the insulator 3 including the elastic deformation portion 3h with a highly flexible elastic member, and the restriction on the material used can be relaxed.

In the first and second embodiments, the movable guide portion 3e is connected to the common connecting portion 3f, but the same number of elastically deforming portions as the movable guide portion are connected to the same number of connecting portions as the movable guide portion. Or you may connect a movable guide part directly. In other words, the movable guide portions may be displaceable independently of each other.
In the first and second embodiments, the elastic deformation portions 3d and 3h are disposed between the adjacent movable guide portions 3e in the width direction of the coil end connection portion 3b. For example, adjacent elastic deformation portions may be integrated. However, in order to facilitate elastic deformation, the width dimension of the elastic deformation portion is preferably smaller than the width dimension of the joint portion.
Furthermore, in Embodiment 1, 2, although the fixed guide part 3g was provided in the coil end connection part 3b, the fixed guide part 3g can also be abbreviate | omitted.
Furthermore, FIG. 18 is an explanatory view schematically showing the main part of FIG. The displacement direction of the movable guide part due to the elastic deformation of the elastic deformation part may be in the direction of the dominant angle range α by the terminal conductor part hung on the movable guide part, and does not necessarily have to be the direction approaching the iron core. For example, in the case of the first embodiment, it is possible to configure the movable guide part and its related structure by rotating 90 degrees by changing the way the terminal conductor part is hooked to the movable guide part from both sides to one side. .
For this reason, the elastic force generated by the elastic deformation of the elastically deformable portion only needs to act in the direction of the inferior angle range β by the terminal conducting wire portion applied to the movable guide portion. Further, in the elastic deformation step in the method of manufacturing a coil device according to the present invention, the movable guide portion may be displaced in the direction of the dominant angle range α by the terminal conducting wire portion hung on the movable guide portion. Further, in the restoration step, the movable guide portion may be returned to the direction of the inferior angle range β by the terminal conducting wire portion hung on the movable guide portion.
In the first and second embodiments, the winding portion 3a is disposed inside the iron core 2, but the present invention can also be applied to a stator in which the winding portion is disposed outside the iron core. That is, a configuration in which the inner diameter side and the outer diameter side in FIGS. Moreover, the structure expand | deployed in strip | belt shape may be sufficient.
Furthermore, although a resolver stator has been described as an example for carrying out the present invention, the present invention can also be applied to a coil device that is not usually called a stator, such as a movable iron core type electromagnetic actuator. Needless to say.

Claims (7)

An iron core having a plurality of teeth,
A coil group having a plurality of winding portions provided in the teeth portion, and a plurality of terminal conductor portions drawn from the winding portion, and a plurality of terminals to which the terminal conductor portions are connected A coil end connecting portion provided with a terminal,
The coil end connection portion is
A connecting portion main body fixed to the iron core and provided with the terminal;
A coil device comprising: a movable guide portion connected to the connection portion main body via an elastic deformation portion, the terminal lead wire portion being hooked to guide the terminal lead wire portion to the terminal.   The coil device according to claim 1, wherein the movable guide portion is displaceable in a direction of a dominant angle range by the terminal conducting wire portion hung on the movable guide portion by elastic deformation of the elastic deformation portion. The coil end connection portion is provided with a through hole,
The elastic deformation portion is disposed in the through hole,
The coil device according to claim 1 or 2, wherein a jig for elastically deforming the elastic deformation portion can be inserted into the through hole. The elastic deformation portion is a spring portion made of an elastic member,
The elastic force generated by the elastic deformation of the elastic deformation portion acts in a direction of an inferior angle range by the terminal conducting wire portion applied to the movable guide portion. Coil device. An iron core having a plurality of teeth,
A coil group having a plurality of winding portions provided in the teeth portion and a plurality of terminal conducting wire portions drawn from the winding portion, and a plurality of terminals to which the terminal conducting wire portions are connected A method of manufacturing a coil device including a coil end connection portion provided with a terminal,
An elastic deformation step of elastically deforming an elastic deformation portion provided in the coil end connection portion and displacing a movable guide portion connected to the elastic deformation portion;
A connecting step of hooking the terminal conductor portion on the movable guide portion and connecting the terminal conductor portion to the terminal;
A restoration method of forming a slack in the terminal conducting wire part by restoring the elastic deformation part and returning the movable guide part. In the elastic deformation step, the movable guide portion is displaced in a direction of a dominant angle range by the terminal conducting wire portion hung on the movable guide portion,
The method of manufacturing a coil device according to claim 5, wherein in the restoration step, the movable guide portion is returned in a direction of an inferior angle range by the terminal conducting wire portion hung on the movable guide portion. In the elastic deformation step, the elastic deformation portion is elastically deformed by inserting a jig into the coil end connection portion,
The method for manufacturing a coil device according to claim 5 or 6, wherein, in the restoration step, the elastic deformation portion is restored by removing the jig from the coil end connection portion.

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