JPH09271157A - Manufacture of cup-shaped multiple coreless armature coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the number of windings of a coil, and improve the rotation efficiency of a motor, by cutting each tap in the middle, and wiring the inner- layer part and the outer-layer part of each segment in series, and connecting them to the cut pieces of a commutator separately for each segment. SOLUTION: A coil 0.05mm in wire diameter is used, and it is made into three segments, and a coil tap part is led out in the middle, and it is wound twice. Next, this tap part is cut in the middle, and the end of winding of the inner layer at the first segment is wired to the beginning m of winding of the outer layer, and the end n of this winding is wired to the beginning o of winding of the inner layer at the second segment though the connection with a commutator cut piece x, and next the end p of winding of the inner layer of the second segment is wired to the beginning of the winding of the outer layer. In the same way, it is wired such that q-r-commutator cut piece y-s-t-u-v-commutator cut piece z-w. Hereby, the number of windings of the coil can be increased, so the balance of the ratio of magnetic charge to electric charge can be improved, and the improvement of output of a motor can be materialized.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an armature coil of a cup-shaped ironless core motor.

[0002]

2. Description of the Related Art A cup-shaped cylindrical ironless core motor has features such that the rotor armature has a very small moment of inertia because there is no iron core in the rotor, there is no cogging, and the efficiency is small and the output is large. , Various winding methods have been proposed. One of the conventional tortoiseshell cup-shaped armature coils
As one manufacturing method, as shown in FIG. 2 (d), a self-bonding magnet wire 1 having a predetermined diameter is wound around a hexagonal shell 3 having a hexagonal cross section and divided into predetermined sections. Wind while tapping. Next, the two surfaces facing each other except for the hexagonal hollow coil which is tapped are bonded tape 2
Etc., and then hold the coil fixed and remove it from the bobbin.

This hollow hexagonal temporary coil that has been removed is flattened and the shape collapses as it is, so it is hot pressed.
(e). This flat coil is wound around a core metal having a predetermined diameter and rolled to form a hollow cylindrical coil (f). Fix both ends of the flat coil and harden it into a hollow cylinder by baking. Then, the respective taps are twisted and connected to form a hollow ironless core armature.

However, in such a structure,
Since the coil is inserted between the field magnet and the housing, its thickness is limited and there is a drawback that it cannot be freely wound. In miniaturizing the coreless motor, the energy product of the field magnet has been improved considerably by using the rare earth magnet, but the magnetomotive force of the rotor on the coil side has not been improved so much.

That is, although the magnetic loading could be improved in the miniaturization, the electric loading could not be improved, and the improvement of the motor output cannot be achieved by the optimum design unless the ratio of the magnetic loading and the electric loading is balanced. Therefore, how to increase the radial thickness of the cylindrical coil in order to appropriately widen the gap length between the magnet and the housing and increase the amount of copper in the coil has been a major problem.

By the way, in the armature winding of the cup-shaped cylindrical ironless core motor, the rotor having a two-layer structure in which the diameter of each molded body is changed to fit one into the other in order to increase the number of windings of the coil. An armature has been proposed. FIG. 3 is an example of that, but in order to superimpose two coils having different diameters, it is necessary to finish the inner diameter and outer diameter tolerances with high precision. Due to the contact between the inner layer coil and the outer layer coil during insertion,
There is a problem that an electrical short circuit occurs (see Japanese Patent Laid-Open No. 53-55716). An object of the present invention is to further increase the number of windings of a coil and improve the rotation efficiency of a motor.

[0007]

According to the present invention, a coil wound in a hexagonal shape is multiply wound in a spiral shape in order to increase the number of windings in a band shape, and the coil is wound in a hexagonal hexagonal winding shape. While attaching, tap the wire at the position corresponding to each segment to form a hexagonal spiral coil coil, then remove it from the winding die and press it to form a flat coil coil, which is then formed into a cylindrical shape. Double-winding or more to form a cup-shaped ironless core armature, cut each tap in the middle, connect the inner layer portion and outer layer portion of each segment in series, and connect each segment to a commutator segment.

[0008]

EXAMPLE As an example of the present invention, the coil wire diameter is 0.05.
The coil tap portion was pulled out in the middle as 3 segments, and was double wound. FIG. 1 (a) is a perspective view of the hollow cylindrical coil. Next, the tap portion is cut in the middle, and the winding end l of the inner layer of the first segment is connected to the winding start m of the outer layer as shown in FIG. 1 (b), and the winding end n is connected to the commutator section x. 2 through connection with
Connect the winding start o of the inner layer of the segment to the winding start p of the inner layer of the second segment to the winding start q of the outer layer. Similarly, qr-commutator intercept y-st-
Connect with uv-commutator section zw. By thus connecting the inner layer and the outer layer of each segment in series, a multiple hexagonal hollow cylindrical coil is formed. Figure 2 (c)
Is a schematic diagram of the connection method.

After using this coil to complete a coreless motor having a diameter of 4.2 mm, the performance as a motor was confirmed, and the motor characteristics shown in Table 1 were obtained. As a comparative example, an example of a single-winding coreless motor having the same diameter as the conventional winding method is shown. As is clear from the table, a 10 to 20% improvement in characteristics was obtained compared to the conventional example.

[0010]

[Table 1]

[0011]

According to the present invention, since the number of turns of the coil can be increased, the balance of the ratio of magnetic loading and electric loading can be improved, the motor output can be improved, and the cylindrical hexagonal hexagonal coil can be realized. The effective magnetic field of the motor can be maximized and the rigidity of the coil itself can be improved by aligning one side of the coil wire with the direction of the generatrix. Moreover, the coil current could be reduced by the serial connection.

[Brief description of drawings]

FIG. 1 is an embodiment view of a cup-shaped cylindrical multiple ironless armature according to the present invention.

FIG. 2 is a schematic view showing a manufacturing method of a hexagonal cup-shaped armature coil.

FIG. 3 is a perspective view of a conventional rotor armature having a two-layer structure.

[Explanation of symbols]

 1 Magnet wire 2 Adhesive tape 3 Reel 4 Inner layer coil 5 Outer layer coil x, y, z commutator section

Claims (1)

[Claims] 1. A method of manufacturing a coil in a cup-shaped multiple coreless armature, comprising: winding a hollow cylindrical cylindrical armature coil having a number of poles of three or more and multiple layers on a flat plate; While winding the coil around the square hexagonal winding form,
Draw a tap wire at the position corresponding to each segment to form a hexagonal spiral coil wire, then remove from the winding form,
It is pressed to form a flat coil wire loop, which is wound into a cylindrical shape and wound in multiple layers to form a cup-shaped coreless armature, and each tap is cut in the middle to form the inner and outer layers of each segment. Is connected in series and each segment is connected to a commutator section.