JPH045811A - Manufacture of hollow coil - Google Patents

Abstract

PURPOSE:To eliminate that a step is collapsed at both ends of an insulated conductor and to easily execute a lined-up winding operation by a method wherein winding faces of coils are brought into contact in such a way that winding directions of insulated conductors are different and winding ends of individual adjacent flat boardlike coils are bonded. CONSTITUTION:A flat boardlike coil 10 is manufactured in such a way that an insulated conductor whose cross-sectional shape is flat is wound to be a spring shape in a hollow disk shape. When a two-row wound hollow coil is manufactured from a plurality of flat boardlike coils 10, corresponding faces 10c are brought into contact with each other in such a way that winding directions of insulated conductors at the adjacent coils 10 are different from each other; individual protrusion parts 10b are coupled at side faces; after that, coupled parts 10d at tips of the coupled protrusion parts 10b are bonded by a TIG welding operation. When an n-row wound hollow coil is manufactured, n pieces of coils are prepared, winding directions of individual adjacent coils 10 are reversed, winding faces 10c are brought into contact with each other, n-2 pieces of coils 10 situated in the middle are used as a mutually adjacent coil pair, a protrusion part 10b and an outer end part 10e of each coil pair are bonded sequentially, and the hollow coil is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a hollow coil for use in electrical equipment, particularly large electrical equipment.

(Prior Art) A hollow coil, for example, a hollow coil 1 shown in FIG. 9 in which N layers of insulated conductors are wound in the radial direction and n rows of insulated conductors in the axial direction is manufactured as follows.

That is, around a predetermined winding jig (not shown), the first
As shown in Figure 0, the insulated conductor 2 is traversed from the winding start position 2a in the direction of arrow A, wound in n rows in the axial direction to form the first layer, and then traversed in the opposite direction in the direction of arrow B. Wind in n rows to form a second layer. Thereafter, such a winding operation is repeated to produce a hollow coil 1 in which the insulated conductor 2 is wound in N layers and in n rows.

(Problem to be Solved by the Invention) By the way, when manufacturing such a hollow coil, if the insulated conductor has a rectangular cross-sectional shape, it is difficult to wind it in an aligned manner due to the influence of the rigidity of the insulated conductor, the curvature accompanying the winding, etc.

In particular, at the ends of an insulated conductor where the traverse direction is reversed,
There has been a problem in that overlapping windings, so-called step-drops, occur and the quality and productivity of the hollow coil are significantly impaired.

In addition, when manufacturing a double-row disc-wound hollow coil in which a plurality of insulated conductors are sequentially wound in two rows, first, one turn of the insulated conductor is wasted, and then the waste-wound insulated conductor is continuously wound. A complicated process is adopted in which two rows of insulated conductors are wound, and then another insulated conductor is wound on top of the insulated conductors to complete a two-row disc-wound hollow coil.

The present invention has been made in view of the above points, and it is an object of the present invention to provide a method for manufacturing a hollow coil that does not have step drops at both ends of an insulated conductor, allows easy aligned winding, and has high productivity.

(Means and Effects for Solving the Problems) To achieve the above object, the present invention provides a method for manufacturing a hollow coil in which insulated conductors are arranged in multiple layers in the radial direction and in multiple rows in the axial direction. A plurality of flat coils each having a conductor wound in a spiral shape are arranged such that the winding surfaces of the insulated conductors are in contact with each other so that the winding directions are different, and the winding ends of adjacent flat coils are joined to each other. be.

In the hollow coil manufacturing method of the present invention, it is first necessary to manufacture a hollow flat coil.

This flat coil is manufactured, for example, by winding an insulated conductor with a rectangular cross-sectional shape into a hollow disk-like spiral shape, as shown in FIG. At this time, in the flat coil 10,
As a bonding margin, a protrusion 10b is formed by bending the inner end of the insulated conductor toward the center of the hollow portion 10a.

Here, the flat coil may have any shape, such as a hollow triangular shape, a hollow square shape, or a hollow hexagonal shape, depending on the shape of the hollow coil to be manufactured, in addition to the hollow disc-like spiral shape shown in Fig. 1. .

For example, in order to manufacture the two-row hollow coil shown in FIG. 2 from the plurality of flat coils IO, the winding direction of the insulated conductors in adjacent coils 10 and 10 is different from each other, as shown in FIG. As shown, the protrusions 10b are engaged after the corresponding winding surfaces 10c are brought into contact with each other and each protrusion fob is engaged on the side surface.

Welding the engagement portion 10d and IOd at the tip of 10b, for example, T
Join by IG welding.

When manufacturing a hollow coil with n rows of windings, prepare n flat coils 10 as shown in FIG. In addition, as shown in FIG.
Two flat coils 10 are arranged, and the adjacent flat coils 10 and 10 are used as a coil pair, and the protrusion 1 of each coil pair is
0b and the outer end portion 10e are successively welded and joined together to form a hollow coil. At this time, the outer ends 10e of each adjacent coil pair are covered with an insulating material such as an insulating tape.
Insulate with.

As the insulating material 11, for example, a sheet of polyamide nonwoven fabric or the like is used.

(Examples) Example 1 An insulated aluminum conductor was spirally wound for 30 turns to produce a hollow rectangular flat coil 20 shown in FIG. The insulated aluminum conductor used had a rectangular cross-section (5 x 8 mm), and the surface was coated with an aromatic polyamide nonwoven fabric (
(Product name: Nomex) An insulating material made of epoxy prepreg wrapped with tape. In addition, the flat coil 2
0 is the horizontal length of the hollow portion 20a as shown in the figure.
= 450 mm, vertical length: L = 500 mm, and set the inner end of the insulated aluminum conductor to the horizontal center position (
-1/2β) toward the center of the hollow portion 20a to form a protruding portion 20b.

Two of these flat coils 20 are prepared, and as shown in FIG. 6, the winding directions are reversed and the winding surfaces 20c are brought into contact with each other,
The side surfaces of both protruding parts 20b, 20b were engaged, and the engaging parts 20d, 20d at the tips were joined by TIG welding.

The resulting double-row disc-wound hollow coil is a perfectly aligned winding.
The appearance was also good. Furthermore, in the method of the present invention, the number of steps required for welding the flat coils 20 together is increased. However, by using the flat coil 20 manufactured in advance, the manufacturing operation of the hollow coil was much easier than when winding a single strip of insulated aluminum conductor.

Example 2 An insulated aluminum conductor with a rectangular cross-sectional shape (5.5 x 6° 7 mm) and tape-wrapped with the same insulating material as in Example 1 was wound with 150 turns, and the inner end of the insulated aluminum conductor was wound in the center direction. The first protrusion 10b has a protrusion 10b bent to
A flat coil 10 having the same configuration as the figure was manufactured.

Sixteen of these flat coils lO are prepared, and first, the first row of flat coils (hereinafter simply referred to as "first row coils") 1
0 and the second row coil 10 were wound in opposite directions, and the winding surfaces 10c and the protrusions 10b were brought into contact with each other.

Next, a second
The side surfaces of the protruding parts 10b of the row coils 10 were engaged, and the engaging parts 10d at the tips were welded and joined.

Next, the winding surface 10c of the third row coil 10 was brought into contact with the winding surface 10c of the second row coil 10 with the winding direction reversed. Therefore, the third row coil IO has the same winding direction as the first row coil 10. In this state, the first row coil IO and the third row coil 10 are connected to the outer end portion 1, respectively.
0e and the engaging portion 10d at the tip of the protruding portion 10b were welded together.

Thereafter, the first row coil IO was brought into contact with the third row coil IO with the winding direction reversed, and the engaging portions 10d of both coils 10° IO were welded together. At this time, both coils 10.10
The outer ends 10c of each were insulated with an insulating material 11 such as an insulating tape.

Next, the winding direction is reversed, and the fifth row coil 10 is brought into contact with the fourth row coil 10.
The row coil 10 was welded together at the engaging portion 10d and the outer end portion 10c.

Thereafter, the winding ends of the 6th row coil 10 to the 16th row coil 10 were sequentially welded in the same manner.

The resulting hollow coil with 16 rows of windings had perfectly aligned windings as in Example 1, and was beautifully finished with no droplets.

The hollow coil can be formed into various shapes by using a hollow triangular flat coil 30 or a hollow hexagonal flat coil 31, as shown in FIGS. 7 and 8. Also in this case, each flat coil 30
．． 31, protrusions 30b, 31b are formed at the inner ends of the insulated conductors by bending and protruding toward the center of the hollow parts 30a, 31a.

(Effects of the Invention) As is clear from the above explanation, by using the method of the present invention, it is possible to easily and easily create a hollow coil with no steps at both ends of the insulated conductor and which can be easily wound in perfect alignment. , can be manufactured at low cost with high productivity.

[Brief explanation of drawings]

1 to 8 show embodiments of the present invention.
The figure is a perspective view showing a hollow disc-shaped flat coil, Figure 2 is a perspective view showing a two-row hollow coil manufactured by joining the same coils, and Figure 3 is the hollow coil shown in Figure 2. FIG. 4 is a perspective view showing a hollow coil with n rows of windings manufactured using n flat coils of FIG. 1, and FIG. 5 is a perspective view showing a hollow rectangular flat coil. Perspective view shown, No. 6
The figure is a perspective view showing a two-row hollow coil manufactured by joining the flat coils shown in FIG. 5, and FIG. 7 is a perspective view showing a two-row hollow coil manufactured by joining hollow triangular flat coils. FIG. 8 is a perspective view showing a two-row hollow coil manufactured by joining hollow hexagonal flat plate coils, and FIG. 9 is a perspective view showing a hollow coil manufactured by a conventional manufacturing method. , FIG. 10 is a sectional view taken along line XX in FIG. 9. 10.20,3 20b, 30b. 20 c, 30 c. part (end of winding). 0.31... Flat coil, 10b. 31b...Protruding portion (winding end), 10c.

Claims (1)

[Claims] In a method for manufacturing a hollow coil in which insulated conductors are arranged in multiple layers in the radial direction and in multiple rows in the axial direction, a plurality of flat coils in which insulated conductors are wound in a spiral shape are arranged in different winding directions of the insulated conductors. A method for manufacturing a hollow coil, characterized in that the winding surfaces of the coils are brought into contact with each other and the winding ends of adjacent flat coils are joined together.