JPH03218243A - Manufacture of armature coil of dc motor - Google Patents

Abstract

PURPOSE:To realize a simple and easy process for manufacture of an armature coil having a double-layer structure by a method wherein the axial direction intermediate parts of respective conductor coil wires are the axial direction intermediate parts of inner and outer coil and both the axial direction end parts of the respective conductor coil wires are in parallel with the axial direction. CONSTITUTION:The method of manufacture of an armature coil 14 of the present embodiment is such that the axial direction intermediate parts of respective conductor coil wires 26 and 36 to which ferromagnetic elements 28 and 38 are fixed are the axial direction intermediate parts of an inner coil 20 and an outer coil 30. Further, both the axial direction end parts, i.e., the parts near the inner sides of slit plates 22 and 32 are in parallel with the axial direction. Therefore, in order to insert the coil conductors into the slits 24 or the slits 34 of a pair of slit plates 22 or a pair of slit plates 32, the respective conductor soil wires 26 and 36 can be inserted into the slits of the respective slit plates 22 and 32 which are provided on both axial direction end parts from the same direction simultaneously.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing an armature coil used in a DC motor.

[Prior Art] It is known that armatures used in DC motors include two-layer armature coils outside an armature core.

In this type of armature, a pair of insulating plates are disposed at both axial ends of an armature core made of a ferromagnetic material. Each insulating plate is a circular plate with a slightly larger diameter than the core, and the outer periphery has multiple slits cut out in the radial direction, and each of these slits has a conductor coil wire inside. installed.

The conductor coil wire is an elongated body made of copper, and a ferromagnetic material (iron) is integrally fixed to the middle part in the axial direction.

Both ends of the conductor coil wire in the axial direction are double assembled in the radial direction within the slits of the pair of insulating plates. In other words, the conductor coil wire assembled on the inside forms a cylindrical inner coil arranged around the outer periphery of the core, and the conductor coil wire assembled on the outside of this inner coil (conductor coil wire) forms a cylindrical inner coil arranged around the outer periphery of the core. , an outer coil is formed around the outer periphery of the inner coil and electrically connected to the inner coil.

Furthermore, at both ends in the axial direction of the inner coil and the outer coil (near the inside of the insulating plate), the conductor coil wires are inclined in opposite directions (for example, 60 degrees) and their arrangement positions are advanced to form crossover wires. is formed, which allows the coils within the field to be properly energized.

A conventional DC motor having two armature coil layers, an inner and an outer layer, has advantages such as being small, having high output, and having good response.

[Problems to be Solved by the Invention] However, the conventional armature coil constructed of two layers, an inner and an outer layer, has the disadvantage that the manufacturing process is complicated and the cost is high.

In other words, in conventional armature coils, the plurality of conductor coil wires forming each coil have both ends oriented perpendicularly to the axially intermediate part (ferromagnetic material fixed part) before being assembled to the insulating plate. Because these conductor coil wires were bent (that is, bent in the circumferential direction with respect to the axial direction of the inner and outer coils), it was difficult to position these bent conductor coil wires when assembling them into the slits of the insulating plate. Assembling requires time and effort to ensure assembly accuracy, resulting in high costs.

In addition, in order to solve this problem, Japanese Unexamined Patent Publication No. 63-2
No. 87338 and Japanese Unexamined Patent Publication No. 63-287339,
It has been proposed to form an inner and outer layer coil by arranging a plurality of coil wire sheets consisting of a plurality of coil wires in parallel in a cylinder and twisting them in one direction.

However, in the case of simply twisting as shown in each of the above-mentioned publications, the connecting wire portion 52 of the coil 50 as shown in FIG.
is dented inward, making it difficult to connect and assemble the inner and outer coils.

In consideration of the above facts, the present invention provides a method for manufacturing an armature coil for a DC motor, which can easily and reliably manufacture an armature coil composed of two layers, an inner and outer layer, and which can reduce costs. The purpose is to obtain.

[Means for Solving the Problems] A method for manufacturing an armature coil for a DC motor according to the invention according to claim (1) comprises a conductor coil wire having a ferromagnetic material integrally fixed to the intermediate portion in the axial direction. The ends of the conductor coil wire are formed into a curved shape in advance in the vicinity of both ends in the axial direction other than the ferromagnetic material fixed portion, and the ends of the conductor coil wire are attached to a pair of insulating plates disposed coaxially with each other at both ends in the axial direction of the armature core. After arranging a plurality of sections adjacent to each other in a cylindrical shape along the circumferential direction and assembling the curved section in a state in which the cylindrical diameter is enlarged, the pair of insulating plates are rotated in opposite directions about their respective axes. Twisting the curved portion of the conductor coil wire to produce an outer coil having a cylindrical crossover portion in which the plurality of conductor coil wires are inclined in the twisting direction and the arrangement position is advanced. Then, after incorporating an inner coil in which the direction of inclination of the conductor coil wire in the crossover portion is different from that of the outer coil and which is arranged on the inner periphery of the outer coil, the inner coil is installed inside the outer coil. The conductor coil wire of the inner coil is electrically connected to the conductor coil wire of the inner coil.

Further, the method for manufacturing an armature coil for a DC motor according to the invention according to claim (2) is the method for manufacturing an armature coil for a DC motor according to claim (1), wherein the inner coil is the outer coil. It is characterized in that it is manufactured by the same process as , and a cylindrical crossover section is formed.

[Function] In the method for manufacturing an armature coil for a DC motor according to claim (1), each conductor coil wire has its axially intermediate portion (the ferromagnetic material fixed portion) serving as the axially intermediate portion of the inner and outer coils,
Both axial ends are parallel to the axial middle part, so when inserting the conductor coil wire into the slit of a pair of insulating plates, the conductor coil wire is inserted from the same direction into both insulating plates at the same time. This makes it easy to assemble to the insulating plate and ensures high assembly accuracy.

Further, after the insulating plates are rotated in opposite directions around the axis, crossover wire portions are formed at both ends of the outer coil in the axial direction. Here, in this crossover section,
Since the end of each conductor coil wire is formed into a curved shape in advance and assembled with the tube diameter enlarged, the crossover wire is formed by rotating the pair of insulating plates in opposite directions and twisting the curved portion. During formation, this crossover portion (twisted portion) is formed into a cylindrical shape without protruding inward.

That is, the outer coil formed by a plurality of conductor coil wires has a continuous cylindrical shape with the same diameter from the ferromagnetic fixed part to the connecting wire part, and therefore, the inner coil is inserted inside this outer coil, Can be easily combined. In this way, it is possible to easily and reliably manufacture and process the armature coil having two layers, the inner and outer layers, and the cost can be reduced.

On the other hand, in the method for manufacturing an armature coil for a DC motor according to claim (2), not only the outer coil but also the crossover portion of the inner coil are formed in a cylindrical shape without protruding inward.

That is, the inner coil and outer coil formed by a plurality of conductor coil wires have a continuous cylindrical shape with the same diameter from the ferromagnetic fixed part to the connecting wire part, and therefore,
The inner coil can be easily assembled to the outer periphery of the armature core, and the outer coil can be further assembled to the outer periphery of the inner coil. In this way, it is possible to easily and reliably manufacture and process the armature coil having two layers, the inner and outer layers, and the cost can be reduced.

[Example] FIG. 1 shows an overall perspective view of an armature 10 for a DC moke manufactured by applying the manufacturing method according to the present invention. Further, in FIGS. 2 to 8, the components of the armature 10 are shown according to the manufacturing stage.

The armature 10 includes an armature core 12, an armature coil 14 disposed outside the armature core 12, and a commutator 18. The armature core 12 is made of a ferromagnetic material such as iron and has a cylindrical shape, and a shaft 16 is attached to the armature core 12 .

The armature coil 14 includes an inner coil 20 and an outer coil 30.
It is composed of. As shown in detail in FIGS. 3 and 4, the inner coil 20 has a pair of slit plates 22. As shown in FIGS. Each slit plate 22 is an insulating plate material,
It is formed in a donut shape, and has an inner diameter dimension corresponding to the outer diameter of the armature core 12. On the outer periphery of each slit plate 22, a plurality of slits 24 cut out in the radial direction are formed adjacent to each other over the entire circumference, and a conductor coil wire 26 is inserted into each of these q slits 24. "I'm being kicked."

The conductor coil wire 26 is an elongated body made of copper, and a ferromagnetic material 28 is integrally fixed to the intermediate portion in the axial direction. Further, as shown in FIG. 5, at both ends of each conductor coil wire 26 in the axial direction (near the inside of the slit plate 22), the conductor coil wires 26 are twisted in opposite directions (for example, by 60 degrees). ) A crossover wire portion 26A is formed whose arrangement position is advanced, so that the coil in the field can be appropriately energized.

The slit plate 22, the conductor coil wire 26, and the ferromagnetic material 28 form a cylindrical inner coil 20 arranged around the outer periphery of the armature core 12.

On the other hand, the outer coil 30 has a pair of slit plates 32 similarly to the inner coil 20. Each slit plate 32 is also formed into a doughnut-like shape using an insulating plate material, and has an inner diameter corresponding to the outer diameter of the slit plate 22. The inner periphery 10 of the slit plate 32 has a slit 24 formed on the outer periphery of the slit plate 22.
A plurality of slits 34 cut out in the radial direction are formed adjacent to each other over the entire circumference. Furthermore, a conductor coil wire 36 is attached within each of these slits 34.

The conductor coil wire 36 is an elongated body made of copper like the conductor coil wire 26, and a ferromagnetic material 38 is integrally fixed to the middle part in the axial direction. At both ends (near the inside of the slit plate 32),
A crossover wire portion 36A is formed in which the conductor coil wires 36 are twisted in opposite directions to advance their arrangement positions.

The slit plate 32, the conductor coil wire 36, and the ferromagnetic material 38 form a cylindrical outer coil 30 arranged around the outer periphery of the inner coil 20.

The end of the conductor coil wire 26 that protrudes outward in the axial direction from the slit plate 22 is connected to the end of the conductor coil wire 36 that protrudes outward in the axial direction from the slit plate 32. 1. The armature coil 14 is formed by electrically connecting the coil 20 and the outer coil 30.

Furthermore, a commutator 18 is provided for each predetermined number of these internal and external connections.
electrically connected to segment 19 of.

Next, a method of manufacturing the armature 10 having the above configuration will be explained with reference to the drawings.

As shown in FIG. 2, the ferromagnetic material 28 of the conductor coil wire 26
The curved portion 25 is formed by pre-curving the vicinity of both ends in the axial direction other than the fixed portion. Furthermore, this curved portion 25
Cuts 40 and 42 are formed on opposite sides of each other at both ends (that is, at the boundary with the straight portion). In addition,
In this embodiment, the depth of these cuts 40 and 42 is within 20% of the thickness of the conductor coil wire 26, but this varies depending on the material and the like.

Next, as shown in FIG. 3, the ends of the conductor coil wire 26 are assembled into the slits 24 of the pair of slit plates 22. Further, as shown in FIG. 4, the pair of slit plates 22 are rotated in opposite directions (in the direction of arrow A in FIG. 4) to twist the curved portion 25 of each conductor coil 1 2 wire 26. by the fifth
As shown in the figure, an inner coil 20 having a crossover portion 26A is formed.

On the other hand, as shown in FIG. 6, the ends of the conductor coil wires 36 are assembled into the slits 34 of the pair of slit plates 32, and as shown in FIG. The curved portion 35 of each conductor coil wire 36 is twisted by rotating it in the direction of arrow B in the figure, and the outer coil 30 is formed by the same process as described above. In this case,
The twisting direction of the pair of slit plates 32 is opposite to that of the slit plate 22 described above, so that
The inclination direction of the conductor coil wire 36 in the crossover wire portion 36A is made to be different from that in the crossover wire portion 26A of the inner coil 20.

Next, as shown in FIG. 8, the inner coil 20 is installed on the outer periphery of the armature core 12, and the outer coil 30 is installed outside the inner coil 20.
The conductor coil wire 26 of the outer coil 30 and the conductor coil wire 3 of the outer coil 30
6 are electrically connected 13 , and a predetermined number of the above-mentioned inner and outer coil connecting portions are electrically connected to the segments 19 of the commutator 18 by welding or the like, thereby completing the manufacture of the armature 10 .

In this way, the above armature coil 14 (armature 10)
In the manufacturing method, each conductor coil wire 26, 36 has its axially intermediate portion (ferromagnetic material 28, 38 fixed portion) as the axially intermediate portion of the inner coil 20 and outer coil 30, and the axially intermediate portion thereof is On the other hand, since both ends in the axial direction are parallel to the axis, when inserting into the slit 24 or 34 of the pair of slit plates 22 or the pair of slit plates 32, each slit plate located at both ends in the axial direction 22
, 32, the conductor coil wires 26, 36 can be inserted simultaneously from the same direction, making positioning easy and ensuring high assembly accuracy.

Furthermore, after each pair of slit plates 22 and 32 are rotated in opposite directions, the inner coil 20 and the outer coil 3
0, crossover wire portions 26A, 36A are provided at both ends in the axial direction, respectively.
is formed. Here, in the crossover wire portions 26A and 36A, the ends of the respective conductor coils 14 and the coil wires 26 and 36 are curved in advance to form the curved portions 26A and 36A.
5 and 35 are formed, the slit plate 22 or 32 is rotated in opposite directions to twist the curved portions 25 and 35 to form the crossover portions 26A and 36.
When forming A, as shown in FIG.
A and 36A (twisted portion) are formed into a cylindrical shape without protruding inward.

That is, the inner coil 20 and the outer coil 30 formed by the plurality of conductor coil wires 26 and 36 are connected to the ferromagnetic material 2.
8, 38 from the fixed portion to the crossover wire portions 26A, 36A are continuously cylindrical with the same diameter. Therefore, the inner coil 20 is attached to the outer periphery of the armature core 12, and the outer coil 30 is attached to the outer periphery of the inner coil 20. Can be easily combined.

In addition, the curved portions 25 and 3 of each conductor coil wire 26 and 36
Since notches 40 and 42 are formed on opposite sides of both ends (border areas with the straight portions) of 5, the curved shapes @25 and 35 are twisted to form crossover portions 26A and 36A. When forming, the curved portions 25, 35 of the conductor coil wires 26, 36 can be bent uniformly and reliably. Therefore, the ferromagnetic material 28
, 38 are not bent and deformed, processing accuracy is improved, and the field paths of the inner coil 20 and the first side coil 30 can be reliably configured to be continuous.

In this way, the two-layered armature coil 14, the inner and outer layers, can be fabricated easily, reliably, and with high precision, and costs can be reduced.

In this embodiment, the inner coil 20 and the outer coil 30 that constitute the armature coil 14 are manufactured in the same manufacturing process, that is, the curved portions 25 and 35 are formed on the conductor coil wires 26 and 36, and Although the configuration is such that the cylindrical crossover wire portions 26A and 36A are formed together by twisting, the configuration is not limited to this, and the configuration may be such that the cylindrical crossover wire portion 36A is formed only on the outer coil 30. Even in this case, the inner coil 30 is placed inside the outer coil 20 formed in a cylindrical shape.
can be easily combined.

1 6 [Effects of the Invention] As explained above, the method for manufacturing an armature coil for a DC motor according to the present invention can easily and reliably manufacture an armature coil composed of two layers, an inner and an outer layer, and can reduce costs. This has the effect of reducing the

[Brief explanation of drawings]

FIG. 1 is an overall perspective view of an armature manufactured by applying the method of manufacturing an armature coil for a DC motor according to the present invention, and FIG. 2 is a perspective view of a conductor coil wire before being assembled to a slit plate. , Figures 3 and 4 are perspective views showing the manufacturing process of the inner coil, Figure 5 is a front view of the completed inner coil, and Figure 6 is a perspective view showing the manufacturing process of the inner coil.
7 and 7 are perspective views showing the manufacturing process of the outer coil, FIG. 8 is a perspective view showing the inserted state in the assembly process of the inner coil and the outer coil, and FIG. 9 is a front view of the coil according to the conventional example. be. 10... Armature, 12... Armature core, 14... Armature Koinobe 17 18 ・ ・ 20 ・ ・ 22 ・ ・ 25 ・ ・ 26 ・ ・ 26A ・ 28 ・ ・ 30 ・ ・ 32 ・ ・ 35・ ・ 36 ・ ・ 36A ・ 38 ・ ・ ・ Commutator, ・Inner Koinope slit plate, ・Curved portion, ・Conductor coil wire, ・Connection wire portion, ・Ferromagnetic material, ・Outer coil, ・Slit plate,・Curved portion, ・Conductor coil wire, ・Cover wire portion, ・Ferromagnetic material.

Claims (2)

[Claims] (1) A conductor coil wire, in which a ferromagnetic material is integrally fixed to an intermediate portion in the axial direction, is formed into a curved shape in advance in the vicinity of both ends in the axial direction other than the portion to which the ferromagnetic material is fixed, and the axial direction of the armature core is A plurality of end portions of the conductor coil wire are arranged adjacently in a cylindrical shape along the circumferential direction on a pair of insulating plates disposed coaxially with each other at both end portions, and the curved portion expands the cylindrical diameter. After the pair of insulating plates are assembled in this state, the pair of insulating plates are rotated in opposite directions around their axes to twist the curved portion of the conductor coil wire, whereby the plurality of conductor coil wires are twisted in the torsional direction. An outer coil having a cylindrical crossover portion whose arrangement position is advanced by being inclined toward the outer coil is fabricated, and then the inclination direction of the conductor coil wire in the crossover portion is different from that of the outer coil, and the inside of the outer coil is An armature for a DC motor manufactured by incorporating an inner coil disposed around the outer coil inside the outer coil and then electrically connecting a conductor coil wire of the outer coil and a conductor coil wire of the inner coil. How to make a coil. (2) The method for manufacturing an armature coil for a DC motor according to claim (1), wherein the inner coil is manufactured by the same process as the outer coil to form a cylindrical crossover portion. .