JPH0328899B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Technical Field The present invention relates to an electric iron core armature used in coreless motors, servo motors, etc., and a method for manufacturing the same.

Prior art As this type of technology, for example, Japanese Patent Application Laid-Open No. 55-144754
As shown in Fig. 1, the coil shown in Japanese Patent Application Laid-Open No. 56-66149 has a spiral outer cylindrical coil 1 twisted by about 180 degrees, and a spiral inner cylinder twisted by 180 degrees in the opposite direction. A coil 2 was formed, and the overlapping portions of these coil end faces were joined to form an electrically closed loop. In such conventional coils, both ends of the coil are wound in a spiral shape, so when welding the end faces with the laser welder 3, the second
As shown in the figure, the strands are slanted, so if the positional accuracy is not achieved, a rare shot is required, so an auxiliary material 4 is used as shown in FIG. 3. In this case, the laser must be applied obliquely, which requires greater positional accuracy and increases the number of welding points. There was also a problem with heat balance, which caused problems with welding reliability.

Further, if the phase shift between the inner and outer cylindrical coil wires exceeds 1/2 turn at the end face of the coil, the auxiliary material 4 cannot be attached (see Fig. 4).

However, in the prior art, it has been difficult to reduce the coil wire position accuracy to 1/4 turn or less due to the accumulation of misalignment errors. Therefore, when the inner and outer cylindrical coils are combined, it is difficult to reduce the phase shift to 1/2 turn or less.

Purpose Therefore, the object of the present invention is to reduce the number of welding points in end face welding for joining the inner and outer cylindrical coils, to perform butt welding of the inner and outer cylindrical coil bare wires in end face welding, eliminating the need for auxiliary wires, and further The purpose is to match the phases of the wires at the end faces of the outer and inner cylindrical coils, thereby improving the quality of the coils and the welding reliability.

Embodiment Hereinafter, one embodiment of the present invention will be described based on the drawings. In Fig. 5, one block 11 is made by arranging a certain number of straight wires in parallel and adjoining each other in a sheet form and gluing them together.
Then, the multiple blocks are arranged adjacently in a cylindrical shape,
Both end portions of this cylindrical body face in the axial direction of the wire, and the middle portion is twisted at 180 degrees to form an outer cylinder, which is a first cylinder 10. In addition, the middle part of the cylindrical body is twisted 180 degrees in the opposite direction to the above-mentioned direction ± the length of one strand, and the other part is a second cylinder 20 similar to the first cylinder 10, which is an inner cylinder, inside the outer cylinder. Make contact and fit.

Here, a gap S is left between each block at both end portions of both cylinders. This gap S is
This is the difference between when wires of the same width are twisted spirally and when they are oriented in the axial direction.
In the book, it is about several tens of micrometers, but it can be expanded to about several hundred micrometers by gathering strands of wire. Now, as shown in Fig. 6, if the wire width is t and the spiral twist angle is α, then the gap dS for one wire is t/cos ^{= -t} , so the number of wires in one block is n.
Then, the gap within one block can be calculated as nt (1/cos〓 ^-1 ). When the coil is completed, a spacer 30 made of plastic or the like is placed in this gap S.
is filled.

Next, as shown in FIG. 7a, at one end of both cylinders 10 and 20, the wires of both cylinders completely overlap each other in the radial direction of each block.

Further, as shown in FIG. 7b, the phases are shifted by one wire at the other ends of both cylinders 10 and 20.

Therefore, as shown in FIG. 8, at both end portions of both cylinders 10 and 20, the insulation coating is removed from the portion where the wires overlap in the radial direction of the cylinders, and by applying pressure in the radial direction of the cylinders, butt welding is performed using a laser. It is joined by Further, as shown in FIG. 7b, the phase-shifted wires are connected to both cylinders by jumper wires 40 or the like.
It is joined at 0.20. With this, both cylinders 10,
20 forms an electrically closed loop.

Note that it is sufficient that either one of the intermediate portions of the first cylinder 10 and the second cylinder 20 is twisted by 180 degrees, and the other is twisted by 180 degrees ± one strand in the opposite direction.

Next, a first method of manufacturing the coil of the present invention will be explained. As shown in FIG. 9, one block 21 is formed by arranging a certain number of straight wires adjacent to each other in a parallel sheet shape and bonding them together. Then, the plurality of blocks are arranged in a cylindrical shape around the cylindrical core metal 5. At this time, as shown in FIG. 10, spacers 6 located at both ends of the metal core are sandwiched. Then, as shown in Figure 11, fix both ends of the coil with clamps 7, shorten the length by twisting, twist 180 degrees ± the length of one wire, and when the coil length is determined, glue the entire coil. etc., and remove the clamp 7 to form the second cylinder 20, which is the inner cylinder. Further, the first cylinder 10, which is an outer cylinder, is formed in the same manner as above by twisting it 180 degrees in the opposite direction.

Then, as shown in FIG. 12, the two cylinders 10, 20
are brought into contact fit with each other. Then, as shown in Fig. 7a, the wires of both cylinders are made to overlap in the radial direction of the cylinders for each block at one end of both cylinders, and the phase is shifted by one strand at the other end of both cylinders, as shown in Fig. 7b. Ru. Next, at both ends of both cylinders, the parts where the wires overlap in the radial direction of the cylinders are welded together using a laser or the like, as shown in Fig. 8, and at the other ends of both cylinders, as shown in Fig. 7b, The shifted strands are joined with a jumper wire 40 or the like to form an electrically closed loop.

Next, a second manufacturing method for the coil of the present invention will be explained. As shown in Fig. 13, a certain number of straight wires 22 are arranged in parallel sheets adjacent to each other and glued together, and as shown in Fig. 14, a plurality of straight wires 22 are bent into a lightning bolt shape on a certain plane and arranged in the same position. A single flat plate 23 is formed and bent into a cylindrical shape as shown in FIG. 15 to obtain a plate 20 corresponding to the first cylinder and second cylinder. Here, when bending the flat plate into a cylindrical shape, if the flat plate is attached to a thin film and bent,
It can be made into a cylindrical shape with high precision.

Note that in the first manufacturing method, fins or pins protruding from the metal core may be used as the spacer 6. Alternatively, instead of bonding to form a sheet, a fixed number of wires may be arranged in blocks in a cylindrical shape.

In the second manufacturing method as well, a large number of wires may be bent one by one into a lightning bolt shape and arranged in parallel to form a plate shape.

Effects As described above, in the armature of the present invention, both end portions of the inner and outer cylinders are oriented in the axial direction of the wires, and the inner and outer cylinder wires overlap, so that butt welding can be performed during welding, making welding easy. At the same time, the strength also improves. Also, since no auxiliary materials are required, the number of welding points can be halved.
This improves the reliability of the armature. Furthermore, since the positional accuracy of the wires in the inner and outer cylinders can be improved, a high-density and well-balanced armature can be formed. Furthermore, by increasing the number of wires in the wire block, it is possible to increase the gap between the inner and outer cylinder ends.
Inner and outer cylinders can be made from flat wire with a large aspect ratio in cross section.

[Brief explanation of drawings]

1 to 4 show the prior art, FIG. 1 is a perspective view of the armature, FIG. 2 is a front view showing the welded part at the end of the armature, FIG. 3 is a sectional view also showing the welded part, and FIG. Figure 4 is an end view showing a welded part, Figure 5 is a perspective view of the armature of the present invention, Figure 6 is an explanatory diagram of dimensions of the end of the armature, Figure 7a is an end view of the armature of the present invention, and Figure 7b is an end view of the armature of the present invention. FIG. 8 is a sectional view of the welded part at one end of the armature, FIGS. 9 to 12 are process diagrams showing the first manufacturing method of the present invention, and FIG. 9 is a perspective view of the sheet.
Fig. 10 is a perspective view showing a part of the sheet placed on the core metal, Fig. 11 is a front view of the inner and outer cylinders twisted together, Fig. 12 is a perspective view of the inner and outer cylinders fitted together, and Figs. 13 is a perspective view of a sheet, FIG. 14 is a perspective view of the sheet as a flat plate, and FIG. 15 is a perspective view of the flat plate bent into a cylindrical shape. 3... Laser welding machine, 5... Cylindrical core metal, 6... Spacer, 10... Outer cylinder, 11... Block, 20... Inner cylinder, 30... Spacer, 40... Jumper wire.

Claims (1)

[Scope of Claims] 1. Consisting of a first cylinder and a second cylinder formed by arranging a certain number of straight wires in parallel and adjacent to each other and arranging a plurality of blocks thereof adjacently in a cylindrical shape, the first cylinder and the second cylinder Both ends of the cylinder face the axial direction of the wire, and the middle part faces the first
Either the tube or the second tube is twisted 180 degrees,
Either one of the blocks is twisted in the opposite direction by 180 degrees ± the thickness of one strand, and a gap is left between each block at both ends,
The two cylinders are fitted in contact with each other, and at one end of the cylinders, the strands of the cylinders overlap in the radial direction of the cylinders for each block, and at the other end of the cylinders, the phases are shifted by one strand. At both ends of both cylinders, the overlapping parts of the strands in the radial direction of the cylinders are joined, and at the other ends of both cylinders, the out-of-phase strands are joined with jumper wires or the like to form an electrically closed loop. A iron-free core armature characterized by: 2 A certain number of straight wires are arranged adjacent to each other in parallel, and a plurality of blocks are arranged in a cylindrical shape around a cylindrical core metal with spacers located at both ends of the core metal, and then these both ends are placed in a cylindrical shape. The coil is fixed and twisted to shorten its length, then twisted at a certain angle. When the length of the coil is determined, the entire coil is fixed with adhesive, and both ends are released to form the first and second tubes. Then, as the fixed angle, either one of the first cylinder and the second cylinder is twisted by 180 degrees, and either one is twisted in the opposite direction by 180 degrees ± the length of one strand, and the two cylinders are fitted into contact with each other. At one end of both cylinders, the strands of both cylinders are overlapped in the cylinder radial direction for each block, and at the other end of both cylinders, the phase is shifted by one strand, and at both ends of both cylinders A ironless core electric machine characterized in that the parts where the wires overlap in the radial direction of the cylinder are joined, and at the other ends of the two cylinders, the phase-shifted wires are joined by jumper wire or the like to form an electrical closed loop. Method of producing children. 3 A certain number of straight wires are arranged adjacent to each other in parallel, and then bent into a lightning bolt shape on one plane, a plurality of them are lined up in the same position to form one flat plate, and this is bent into a cylindrical shape to form the first A cylinder and a second cylinder are formed, both end portions of these cylinders are oriented in the axial direction of the strand, and one of the first cylinder and the second cylinder is twisted by 180 degrees in the middle part,
One of the cylinders is twisted in the opposite direction by 180 degrees ± one strand, and the two cylinders are brought into contact with each other. The two cylinders are made to overlap in the radial direction, and the phase is shifted by one strand at the other ends of the cylinders, and the parts where the strands overlap in the radial direction of the cylinders are joined at both ends of the cylinders, and at the other ends of the cylinders, the phases are shifted by one wire. . A method for manufacturing a iron-free core armature, characterized in that the phase-shifted wires are joined with a jumper wire or the like to form an electrically closed loop.