JPS5872356A - Manufacture of coil for coreless motor - Google Patents

Abstract

PURPOSE:To improve the productivity by forming a cylinder by aligning many coil strands, twisting in the prescribed direction coil strand bonding parts, cutting the twisted part, and forming outer and inner layer coil parts. CONSTITUTION:Many coil strands 6 are disposed and aligned between projections 4 in parallel with an axis at a core 5, thereby forming a cylinder 7 aligned with the strands at the prescribed interval in a peripheral direction. Then, coil strand bonding parts 8 are formed at the prescribed interval in an axial direction, and the parts 8 are twisted to the prescribed direction, the twisted part is cut, thereby forming outer and inner layer coil parts.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a coil for a coreless motor.

In a coil in which an inner layer coil portion and an outer layer coil portion are formed separately, the two are fitted with each other, and the ends of the coil wires appearing at both ends are fitted with each other using a laser or the like to form a closed loop. The winding methods include honeycomb coil 1 as shown in Figs. 1 and 2, hexagonal coil 2 as shown in Figs. 3 and 4, and wave coil 3 as shown in Fig. 5 and @6. etc. are being considered.

However, among these, the hexagonal type and the corrugated type have the disadvantage that they have a higher flux linkage than the honeycomb type, and are more efficient but have poor productivity.

Therefore, an object of the first invention is to provide a method for manufacturing a coil for a coreless motor, which can manufacture coils of hexagonal and wave-shaped winding methods with high production efficiency.

A first embodiment of the first aspect of the invention will be described with reference to FIGS. 7 to 13. That is, this is to form a hexagonal coil, and first, an outer layer coil portion and an inner layer coil portion are formed by the following method. As shown in FIG. 7, a predetermined number of guide protrusions 4 are formed at equal intervals in the circumferential direction, and a plurality of sets of nine core metals 5 are arranged in the axial direction (@FIG. 7). As shown in FIG. 8, a large number of coil elements #I6 can be carried parallel to the axis and positioned between the protrusions 4 on this core metal 5, thereby forming cylindrical bodies 7 arranged at regular intervals in the circumferential direction. . As shown in FIG. 9, fixed portions 8 are formed by fixing coil elements M6 of a predetermined width with adhesive at regular intervals in the axial direction of this cylindrical body 7. As shown in FIG. 10, the fixed parts 8b and gc on both sides of one fixed part 81 are fixed, and the fixed part 8a in the middle is rotated in one direction as shown by the arrow. In this way, the unattached parts 9 and 1o between the attached parts sa and sb and between the attached part 5 assc are twisted spirally, and the attached parts 8b and 8c are drawn to the attached part 8a, and the gap between the coil wires is are narrowed and come into contact with each other. Then, cut 1' 2 at the position PP shown by the dashed line in the center of the unfixed portion 9.10. In this way, the outer layer coil portion 11 or the inner layer coil portion 12 is formed as shown in FIGS. 11 and 12. These outer layer coil portion 11 and inner layer coil portion 12
1d, the outer diameter of the inner coil portion 12 is equal to the inner diameter of the outer coil portion 11, and the flow portion 9.10 is parallel to the fixed portion 9.
are formed so that their inclination directions are opposite to each other.

The outer layer coil portion 11 and the inner layer coil portion 12 are fitted together, and the coil wire ends 13° 14 of the inner and outer layer coil portions 11 and 12 shown at both ends as shown in FIG. 13 are opposed to each other. Join by etc. In this way, a tortoiseshell-shaped coil that becomes a closed loop is formed. A shaft and a commutator are attached to this coil, and the segments and coil terminals are connected to form a motor rotor.

A tortoiseshell-shaped coil with a large amount of magnetic flux linkage can be manufactured continuously, and productivity can be improved.

A second embodiment of the first invention will be explained with reference to FIGS. 14 to 17. That is, this is a wave-shaped coil shaped bz, in which a cylindrical body 16 is formed by the coil wire 15,
The point that fixed parts 17 and unfixed parts 18 are formed at regular intervals is similar to the embodiment @l, and as shown in FIG. 15, one fixed part 17a (7) unfixed parts 188 at both ends,
181) Rotate the adjacent fixed parts 17b so that their spiral winding directions are the same. In contrast to the outer layer coil portion 19 formed in this manner, the inner layer coil portion 2o is the 17th layer coil portion 2o.
As shown in the figure, the winding directions of the unfixed parts 21a and 21b are reversed, and both coils l! I! 19.20 When the gold phase is fitted and the ends of the nine coil wires appearing at both ends are phase-joined, a wave-shaped coil forming a closed loop is obtained. Therefore, it has the same effect as the @l embodiment.

As described above, the method for manufacturing a coil for a coreless motor according to the invention of sl is to form a cylindrical body by diagonalizing coil wires in the circumferential direction at a predetermined interval r4, and forming coil wires at regular intervals in the axial direction. The outer layer coil portion and the inner layer coil portion are formed by forming fixed portions, twisting the fixed portions in a certain direction, and cutting them at the arm portions, making it possible to produce corrugated or tortoiseshell coils with good productivity. There is an effect that can be obtained.

By the way, although the no-nikum type coil has better productivity than the conventional tortoise-shell type coil, it has the following drawbacks in joining the coil wire ends 25 and 26, as shown in Figs. 18 and 19. friend. That is, (1) when the wires of the inner layer coil part and the outer layer coil part are close to each other when the ends are joined, the heat during joining breaks down the insulation coating of the coil wire and - There were many things that caused problems.

(2) When joining the end faces, if the positions of the corresponding coil wires of the inner and outer layer coil parts are shifted by a certain amount in the circumferential direction, joining becomes difficult, so high precision is required in positioning the inner and outer layers. friend.

In order to eliminate these drawbacks in the Shikamo/Nikam type, a pin 28 is embedded in the core bar 27 as shown in FIG. A method has been developed in which the end faces 31 and 32 of the end faces 31 and 32 are joined to each other in parallel to the axial direction as shown in FIGS. By doing this, a gap is formed between the adjacent parts 30' of the coil wire, so the thermal influence during joining is reduced, and some positional deviation between the wires between the inner and outer layers is caused by the wire ft. It can be corrected by @. However, this method has the drawbacks of difficult continuous production and poor productivity.

Therefore, a second object of the invention is to provide a method for manufacturing a coil for a coreless motor, in which the ends of the coil wires can be joined easily and reliably, and the productivity is high.

An embodiment of the second invention will be described with reference to FIGS. 23 to 26. In other words, there are many coil elements on the core metals 33 and 33'! I34 is spirally wound to form a cylindrical body 35 for the inner layer as shown in FIG. 23 and a cylindrical body 36 for the outer layer as shown in FIG.
The cylindrical bodies 35 and 36 have adhesively fixed parts 37 and 37 with a predetermined width spaced apart from each other in the axial direction.
', and then rotate the adjacent fixed parts 37 and 37' in opposite directions as shown by the arrows in FIG.
8 and 38' are screwed back so that they are parallel to the axial direction as shown in FIG. As a result, a gap H is formed between the coil wires in this portion. A circumferential groove (not shown) is formed in the portion of the unfixed portion 38° 38' shown by the dashed line, and the coil wire 34 is stripped and separated by cutting at the circumferential groove. The outer layer coil portion and the inner layer coil portion thus formed are fitted in phase with each other, and both ends of the coil strands, which are parallel to the axis, are welded together to form a coil as in FIG. 22.

With this configuration, the end of the coil has a thermal influence on the adjacent wire due to the gap H when joining the hot water surface! Since it is small, the probability of short-circuiting is reduced and stable bonding can be performed. Furthermore, since the joint line can be moved freely, there is no need for highly accurate positioning of the inner and outer layers. Moreover, the productivity is better than the conventional method shown in FIG. If the circumferential groove is formed before cutting, processing and joining will become easier.

As described above, in the method for manufacturing a coil for a coreless motor according to the second invention, a large number of coil wires are spirally wound to form a cylindrical body, fixed parts are formed at regular intervals, and the fixed parts are rotated. Then, the coil wire in the unbonded part was screwed back so that it was parallel to the axial direction, and this unbonded part was cut to form the inner layer coil part and the outer layer coil part, so that the end joining in the next process was easy. It has the effect of being easy and having good productivity.

[Brief explanation of drawings]

Fig. 1 is a schematic perspective view of a honeycomb coil, Fig. 2 is a developed view thereof, Fig. 3 is a schematic perspective view of a hexagonal coil, Fig. 4 is a schematic perspective view of a hexagonal coil, and Fig. 5 is a schematic perspective view of a wave-shaped coil. Fig. 6 is a developed view thereof, Fig. 71 is a perspective view of the core bar used in the tenth dormitory embodiment of the first invention, and Fig. 148 is a cylindrical body formed by positioning the coil wire on the core bar. Figure 9 is a side view of the state in which the fixed part is formed, Figure 10 is a side view of the unfixed part twisted into a spiral shape, Figure @11 is a perspective view of the outer layer coil part, Fig. 12 (2) is a perspective view of the inner layer coil part, Fig. 13 is a partially enlarged perspective view of the end of the coil part, and Fig. 14 is a side view of the second English-patterned cylindrical body with a fixed part formed thereon. Fig. 15 is a side view of the unfixed part twisted into a spiral shape, Fig. 16 is a perspective view of the outer coil part, Fig. 17 (2) is a perspective view of the inner coil part, and Fig. 18 is the conventional Figure 19 is a perspective view of a partially enlarged end portion of the honeycomb coil, Figure 20 is a perspective view showing how the coil part is formed by another conventional manufacturing method, Section 4g21 is an enlarged perspective view of the main part. Figure, ;s
FIG. 22 is a partially enlarged perspective view of the end of the coil, FIG. 23 is a perspective view of the inner layer cylinder, and FIG. 24 is a perspective view of the outer layer cylinder.
FIGS. 25 and 26 are perspective views showing the process of forming unfixed portions parallel to the axis. 6.15.34... Coil wire, 7, 16... Cylindrical body, 8, 17, 37, 37'... Hard N part, 9.
10°18, 38, 38'...unfixed portion, 11.
19...Outer layer coil part, 12.20...Inner layer coil part, 13.14...End face Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 242-10 Figure 11 Figure 12 L Figure 16 Figure 17 Figure 18 Figure 19 (a) (b) Figure 20 Figure 21 Figure 1 Figure 22 -Mo-

Claims (1)

[Scope of Claims] (1) A coil that forms a closed loop by fitting the separately formed outer layer coil portion and inner layer coil portion, and joining the ends of the coil wires appearing at both ends thereof. A manufacturing method in which a large number of coil wires are arranged in parallel in the axial direction and arranged at regular intervals in the circumferential direction to form a cylindrical body, and the coil wires are arranged in a predetermined width at regular intervals in the axial direction of this cylindrical body. By forming fixed parts, rotating these fixed parts in opposite directions to the neighboring ones to form a spiral part between the fixed parts, and cutting the cylindrical body at this spiral part, the fixed parts are positioned in the center. A method for manufacturing a coil for a coreless motor, which is characterized by forming an outer layer coil portion or an inner layer coil portion. (21ijl) The method for manufacturing a coil for a coreless motor according to claim (1), wherein the winding directions of the spiral portions at both ends of the fixed portion are opposite to each other to form a hexagonal-shaped coil. (3) Claims @(
1) A method for manufacturing a coil for a coreless motor as described in section 1). (4) A method for manufacturing a fill in which a closed loop is formed by fitting together an outer layer coil portion and an inner layer coil portion that are formed separately, and joining the ends of the coil wires appearing at both ends thereof, comprising: A large number of coil wires are spirally wound in the axial direction to form a cylindrical body, and coil wire fixing parts are formed with a predetermined width at regular intervals in the axial direction of this cylinder, and these fixed parts are for a coreless motor, characterized in that adjacent ones are rotated in opposite directions to form a parallel part between fixed parts, and an outer layer coil part or an inner layer coil part is formed by cutting the cylindrical body at this parallel part. How to manufacture coils. (5) A claim in which the parallel portion has a circumferential groove formed in the cut portion to cover the coil wire before cutting!
The method for manufacturing a coil for a coreless motor according to item (4).