JPH01148039A - Manufacture of coil - Google Patents

Abstract

PURPOSE:To improve workability, by forming cut runout previously on the outer periphery of the annular part of a spool. CONSTITUTION:In the manufacturing method of a stator, a spool 12 is prepared and the spool 12 is provided with an annular part 13 and salient poles 14. The salient poles 14 are provided with T-shape rods substantially while slots 15 for winding a coil wire 18 are formed on the outer periphery of the annular part 13. Runout forming members 16 are mounted on the spool 12 respectively and a hollow section is formed by the mounting state of the runout forming members 16 while cut runouts 17 are constituted of the runout forming members. The coil wires 18 are wound around respective salient poles 14. According to this method, the coil wire 18 is wound overriding a plurality of salient poles 14, however, the salient poles 14 are arranged radially and outwardly on the outer periphery of the annular part 13 whereby large spaces are secured at the entrance of the wire in the slots 15 and coil winding works may be effected easily.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a coil, and in particular to an improvement in a method for manufacturing a winding frame around which a coil wire of a coil is wound. This invention relates to materials that can be effectively used to manufacture stators for motors.

[Conventional technology]

As a method of manufacturing a stator for a brushless motor, there is a method as shown in FIG.

That is, a coil wire 5 is wound between each salient pole part 4 around a winding frame 2 in which a plurality of salient pole parts 4 are arranged in a radial shape and protrude from the outer periphery of a narrow ring-shaped part 3, and then ,
The stator 1 is manufactured by fitting the winding frame 2 into the fitting cavity 7 of the outer frame 6 with the front end surfaces of the salient poles in contact with each other.

[Problem that the invention seeks to solve]

However, in such a stator manufacturing method, the width of the ring-shaped part of the winding frame is set to be extremely narrow because it is necessary to configure the stator to be magnetically separated, so the rigidity of the ring-shaped part is If an unexpected external force is applied to the salient pole during handling during winding or winding work, the winding frame is easily deformed, and as a result, it becomes impossible to fit the winding frame and the outer frame. Even if an attempt is made to correct the deformation of the winding frame and fit it into the outer frame, defects such as loosening of the wound coil wire or wire breakage will occur.

Therefore, in order to prevent the deformation of the winding frame, the width of the ring-shaped portion 3A of the winding frame 2A was set sufficiently wide, and the winding frame 2A was fitted into the outer frame 6, as shown in No. 121!1. After that, adjacent salient pole portions 4 in the ring-shaped portion 3A.
By cutting the notches 8 between the stator IA
One possible method is to manufacture

However, in such a method of manufacturing a stator, the notches 8 are cut very close to the wound wire, which not only requires high-precision and high-grade cutting.
Accidents that damage the wound wire occur due to extremely small processing errors.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a coil that can be manufactured with good workability and high precision.

[Means for solving problems]

The method for manufacturing a coil according to the present invention includes a step of forming a winding frame in which a plurality of salient pole parts are arranged in a radial shape and project from the outer periphery of the ring-shaped part, and A process of forming a cutting relief part so as to protrude radially outward between adjacent salient pole parts, a process of winding a coil wire around the salient pole part of the winding frame, and a process of winding the coil wire around the winding frame. and a step in which the ring-shaped portion of the winding frame is cut at a position opposite to the cutting relief portion. Features.

(Function) According to the above-described means, in the process of cutting the ring-shaped portion of the winding frame, a cutting relief portion is formed at the tip where the cutting tool cuts, so that the wound coil wire material is cut by the cutting tool. Accidents of damage due to this will be avoided.

By cutting this ring-shaped part, a magnetic separation part is formed between adjacent salient pole parts, so that the width of the ring-shaped part can be set large in advance. In other words, since sufficient rigidity is given to the winding frame, deformation of the winding frame can be prevented even if an unexpected external force is applied to the salient pole portion during handling such as the winding process. Therefore, in the process of fitting the winding frame into the outer frame, the winding frame can be fitted into the outer frame reliably and accurately.

〔Example〕

FIG. 1 is a partially omitted front view showing a stator obtained by a stator manufacturing method according to an embodiment of the present invention, FIG. 2 is a partially omitted side cross-sectional view, and FIGS. 3 and 4. , Figure 5, Figure 6
7 and 8 are partially omitted front views showing respective manufacturing processes.

In the stator manufacturing method according to this embodiment, first,
A winding frame 12 as shown in FIG. 3 is manufactured. That is, the winding frame 12 has a ring-shaped part 13 formed in a circular ring shape in the front view, and integrally protruding parts arranged in a radial shape at approximately equal intervals in the circumferential direction on the outer periphery of the ring-shaped part 13. The ring-shaped portion 13 has a plurality of salient pole portions 14, and the radial width A of the ring-shaped portion 13 is set wide so as to ensure sufficient rigidity of the ring-shaped portion 13. The salient pole portion 14 is formed into a substantially T-shaped rod shape in a front view, and is integrally provided to protrude from the outer periphery of the ring-shaped portion 13 formed in a cylindrical shape.

On the outer periphery of the ring-shaped portion 13, slot portions 15 for winding one coil wire are substantially formed by spaces between adjacent salient pole portions 14 and 14, respectively.

Further, the winding frame 12 includes a thin plate made of a magnetic material such as a ferrous material and formed into the planar shape shown in FIG. 3 by an appropriate means such as press working. A large number of these thin plates are laminated and integrated to form a substantially cylindrical shape.

As shown in FIG. 4, in the winding frame 12 configured in this manner, the relief portion forming member 16 has slots substantially formed by adjacent salient pole portions 14 and 14 on the outer periphery of the ring-shaped portion 13. It is attached between the sections 15, respectively. That is, the relief part forming member 16 is integrally molded into a bridge shape with a roughly M-shaped cross section using a thin plate having insulating properties such as insulating paper or a glass epoxy insulating board, and has an M-shaped head. After being fitted into the slot portion 15 from the outside so that the head abuts against the outer peripheral surface of the ring-shaped portion 13, the M-shaped legs are inserted into the salient pole portions 14.14 on both sides. They are attached to the slot portion 15 by being engaged with the head, respectively.

In this attached state, the head of the relief part forming member 16 forms a hollow part that is spaced radially outward from the outer peripheral surface of the ring-shaped part 13, and the cutting relief part 17 is substantially constituted by this hollow part. become.

Thereafter, a coil wire 18 made of a conductor such as copper coated with an insulating coating such as enamel is wound around each salient pole portion 14 on the winding frame 12, as shown in FIG.

At this time, the coil wire 18 is not wound into the cutting relief part 17 by the relief part forming member 16.

In this case, as shown in FIG.
8 is wound once across a plurality of salient pole portions 14.14, and the salient pole portions 14 are arranged radially outward on the outer periphery of the ring-shaped portion 13 to protrude. By being
Since a large space is secured at the entrance of the winding in the slot portion 15, the winding work can be easily carried out.

Furthermore, as described above, by setting the width A of the ring-shaped portion 13 sufficiently wide, the rigidity of the salient pole portion 14 is increased, so that during handling such as winding work and transporting the winding frame,
Even if an unexpected external force is applied to the salient pole part 14,
The salient pole portion 14 and the ring-shaped portion 13 are not bent or deformed. Therefore, the occurrence of defects such as inability to perform winding work and loosening of winding of the 1@ wired coil wire material 18 can be prevented.

On the other hand, in the stator manufacturing method according to this example,
An outer frame 20 as shown in FIG. 6 is manufactured. That is, the outer frame 20 is a main body 2 formed in a square shape that is larger than the outer diameter of the winding frame 12 when viewed from the front.
1, a fitting cavity 22 which is arranged concentrically in this main body 21 and is integrally opened in a circular hole having an inner diameter dimension equal to the outer diameter dimension of the winding frame 12, and four corners of this main body 21. Bolt insertion holes 23 for mounting are arranged and opened respectively.
Similar to the winding frame, it is formed into a cylindrical shape by laminating and integrating a large number of thin magnetic plates integrally formed by press working or the like.

The winding frame 12 wound with the coil wire 18 is fitted into the outer frame 20 thus formed, as shown in FIG. 7. That is, the winding frame 12 is connected to the fitting cavity 2 of the outer frame 20.
2, the group of salient pole portions 14 are concentrically fitted into the fitting cavity 22 with the outer circumferential surface thereof abutting the inner circumferential surface of the fitting cavity 22. At this time,
As described above, the winding frame 12 is prevented from deforming its salient pole portion 14 and ring-shaped portion 13, so that it can be easily and precisely fitted into the fitting cavity 22 of the outer frame 20. .

After being fitted into the outer frame 20, as shown in FIG.
．． 14, and is formed by cutting the ring-shaped portion 13 at a position facing the cut relief portion 17 by the relief portion forming member 16. That is, a cutting tool 25 such as a saw blade or the like is disposed on the ring-shaped portion 13 so as to face the cutting relief portion 17 on its inner circumferential surface, and is cut radially outward. At this time, the magnetic separation part 2
4, it is necessary to completely cut off the flesh of the ring-shaped portion 13 using the cutting tool 25.

By the way, in the case of the conventional example in which a cutting relief part is not formed in the ring-shaped part, the coil wire material is wound at the end where the cutting tool cuts, so there is a risk that the coil wire material will be damaged by the cutting tool.

Possible means to avoid this danger include a method of stopping cutting midway through, and a method of extremely high cutting accuracy. However, in the former case, the magnetic separation provided by the separating portion becomes insufficient, and in the latter case, productivity is extremely reduced and costs increase.

In this embodiment, since the cutting relief part 17 is formed by the relief part forming member 16 at the cutting end of the cutting tool 25, even if the cutting tool 25 cuts in order to completely cut the ring-shaped part 13, the coil wire 1B No cutting accidents occur.

That is, the coil wire 1 wound inside the slot portion 15
8 is wound on the outer surface of the relief part forming member 16 on the outer periphery of the ring shape 13, thereby forming the cutting relief part 17.
The cutting tool 25 avoids getting caught in this relief part 17.
It is inevitable that the coil wire 18 will not be damaged even if the coil wire 18 is cut deeply.

By completely cutting the ring-shaped portion 13, magnetic separation by the separation portion 24 is completely ensured, so that the desired performance of the stator can be ensured. Furthermore, since it is possible to tolerate an accident in which the cutting tool 25 is accidentally deeply cut into the cutting relief portion 17, the strictness of cutting precision can be significantly relaxed, and productivity can be increased. can.

In this way, the magnetic separation part 24 is attached to the ring-shaped part 13.
is formed between the salient pole portions 14, 14, thereby producing the stator 11 as shown in FIGS. 1 and 2.

That is, in the fitting recess 22 of the outer frame 20, a plurality of salient pole portions 14.14 are arranged inwardly in a radial shape and protrude from each other, and the adjacent salient pole portions 1'4.14 Magnetic separation portions 24 formed by cutting the ring-shaped portion 13 are interposed between the tip portions, and the salient pole portions 14
A coil wire 18 is wound around the group. In this state, since the relief part forming member 17 fitted into the slot part 15 between the salient pole parts 14 and 14 is made of a magnetically insulating material, the stator formed by this coil is There is no adverse effect on performance.

According to the embodiment described above, the following effects can be obtained.

(1) By inserting the relief part forming member into the slot of the S frame, a cutting relief part is formed on the outer periphery of the ring-shaped part of the winding frame, and by cutting the ring-shaped part of the winding frame, magnetic When forming the separation part, it is possible to form a void where the coil wire is not wound when cutting with the cutting tool, which prevents accidents such as damage to the coil wire wound by the cutting tool. can be avoided.

(2) By completely cutting the ring-shaped part,
Since the magnetic separation by the separation part can be completed, the desired performance of the stator and the motor using the same can be ensured.

(3) By relaxing the cutting precision for forming the separation portion, productivity can be increased and costs can be reduced.

(4) Since a magnetic separation part is formed between adjacent salient pole parts by cutting the ring-shaped part, the width of the ring-shaped part of the winding frame can be set large in advance.

(5) Due to (4) above, sufficient rigidity is given to the winding frame, so even if an unexpected external force is applied to the salient pole part during handling such as the winding process, deformation of the winding frame can be prevented. . Therefore, in the process of fitting the winding frame into the outer frame, the winding frame can be fitted into the outer frame reliably and accurately.

9 and 11 show other embodiments of the present invention, FIG. 9 is a front view showing the cutting relief part forming process, and FIG.
The figure is a partially omitted front view showing the cutting process of the ring-shaped part.

This embodiment differs from the previous embodiments in that the cutting escape portion 27 is formed by a coating layer 26 covering the outer surface of the winding frame 12. That is, the coating layer 26 is made of an insulating resin such as epoxy resin,
When formed on the outer circumferential surface of the winding frame 12 by an integral molding method using a mold or a coating method using dipping, spraying, brushing, etc., the approximate distance between the salient pole portions 14 and 14 on the outer circumference of the ring-shaped portion 13 is formed. By forming the center portion thicker, the cutting relief portion 27 formed by the solid portion of the resin is integrally formed.

Since one coil wire 18 is not wound within the cutting escape portion 27 formed by the resin solid portion, the coil wire is 18, the occurrence of damage accidents can be inevitably avoided. Therefore, the same effects as in the embodiment described above can be obtained.

Note that the present invention is not limited to the above embodiments,
It goes without saying that various changes can be made without further advancing the gist.

For example, the cutting relief part is not limited to a hollow part formed by a relief part forming member made of an insulating plate or a solid part formed by a resin coating layer, but may be formed by another hollow part or solid part.

In the above embodiment, the method for manufacturing the stator of a brushless motor has been described, but the present invention is not limited to this, and can be applied to stators of other motors, rotors of various motors, stators and rotors of generators, etc. It can be applied to all methods of manufacturing coils used.

〔Effect of the invention〕

As explained above, according to the present invention, by forming the cutting relief part in advance on the outer periphery of the ring-shaped part of the winding frame,
Since it is possible to form a complete magnetic separation between the salient pole parts while preventing deformation of the winding frame, it is possible to manufacture a coil with good workability and high precision.

[Brief explanation of the drawing]

FIG. 1 is a partially omitted front view showing a stator obtained by a stator manufacturing method according to an embodiment of the present invention, FIG. 2 is a partially omitted side cross-sectional view, and FIGS. 3 and 4. , Figure 5, Figure 6
7 and 8 are partially omitted front views showing respective manufacturing processes. Fig. 9 and Fig. 1θ show other embodiments of the present invention, Fig. 9 is a front cross-sectional view showing the process of forming a cutting relief part, and Fig. 10 is a partially omitted view showing the process of cutting a ring-shaped part. It is a front view. FIGS. 11 and 12 are partially omitted front views of conventional examples, respectively. 11... Stator (coil), 12... Winding frame, 13...
...Ring-shaped part, 14...Salient pole part, 15...Slot part, 16...Escape part forming member, 17...Cutting escape part (hollow part), 18...Coil wire material, 20 ... Outer frame, 21 ... Main body, 22 ... Fitting recess, 23 ...
Bolt insertion hole, 24... Magnetic separation part, 25... Cutting tool, 25... Coating layer, 27... Cutting relief part (solid part). Agent Patent Attorney Tatsu Kajiwara

Claims (3)

[Claims] (1) A process of forming a winding frame in which a plurality of salient poles are arranged in a radial pattern on the outer periphery of the ring-shaped part, and between adjacent salient pole parts on the outer periphery of the ring-shaped part of the winding frame. The cutting relief part is formed so as to protrude outward in the radial direction, the coil wire is wound around the salient pole part of the winding frame, and the winding frame with the coil wire wound thereon is formed in the fitting hole of the outer frame. and a step of cutting the ring-shaped part of the winding frame at a position opposite to the cutting relief part to form a magnetic separation part. A method for manufacturing a coil characterized by: (2) Manufacture of the coil according to claim 1, wherein the cutting relief portion is constituted by a hollow portion formed by a relief portion forming member fitted between adjacent salient pole portions. Method. (3) The method for manufacturing a coil according to claim 1, wherein the cutting relief portion is constituted by a solid portion of a coating layer deposited on the outer periphery of the ring-shaped portion.