JPS5914344A - Manufacture of flat coil - Google Patents

Abstract

PURPOSE:To manufacture a flat coil which is increased in thickness of bore in simple steps by opening a reference hole for knocking press at a steel plate, punching by knocking press a slit and pressing to reduce the thickness of the plate. CONSTITUTION:A flat plate 18 of steel having the prescribed thickness is prepared, and a reference hole 20 for knocking press is opened at the plate 18. After slits 21 are punched by knocking press at the plate, the plate is annealed at 500 deg.C for 1hr. Then, the plate 18 having inner diameter D1 of the slits is pressed to sequentially reduce the thickness toward the outer periphery. Subsequently, coil strands are fored by punching the plate, thereby manufacturing a flat coil.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a flat coil in which cooling performance is improved by increasing the thickness of the inner diameter portion of the flat coil to disperse heat concentrated in the inner diameter portion.

Applications of the flat coil manufactured by the method of the present invention include printed motors, flat motors, and flat alternating current generators.

This type of flat coil has a plurality of conductors arranged radially on a disc-shaped insulating member. Therefore, the closer you get to the center of this disk, the less insulation space between the conductors.
As a result, the width of the conductor is limited and the effective cross-sectional area of the conductor is reduced.

Therefore, heat generation increases in the conductor part on the center side, increasing power loss.Also, due to the structure of the rotating electrical machine, the center side of the flat coil has a bearing that is a heat source, so it is called cooling 1. This is a problematic part, and the large amount of heat generated in this part has a great impact on the efficiency and durability of the rotating electrical machine.

Furthermore, as print motors and flat motors become more compact and have higher output, the temperature of the entire flat coil tends to rise, and the situation has become such that heat concentration must be prevented.

In view of the above-mentioned problems, there has been a need for a flat coil that improves cooling performance by increasing the thickness of the inner diameter portion of the flat coil to disperse heat concentrated in the inner diameter portion.

Hereinafter, a flat coil having an increased inner diameter portion will be described.

Figure 1 is a front view of the flat coil, and Figure 2 is A-A.
FIG. 2 is a copper plate, 2 is an insulating plate (mica plate, insulating resin plate, insulating cloth, etc.), and 3 is a ceramic adhesive. The copper plate 1 consists of a plurality of blocks of the same shape, and is welded on the front and back sides at the inner and outer peripheral edges 1a and Ib with an insulating plate 2 interposed therebetween, and is fixed by a ceramic adhesive 3 applied to both sides of the insulating plate 2. There is. Further, 1f is a hole in which the rotating shaft of the rotating electric machine is disposed.

FIG. 3 is a front view of only one block of the copper plate 1, that is, a linear coil wire portion, and is composed of a first ineffective portion 1c, an effective portion 1d, and a second ineffective portion 1e on the inner peripheral side. Figure 4 is a side view of one block of the rope plate I, showing the first ineffective portion I.
C is thicker than the effective portion ld. In other words,
As shown in FIG. 1, the width of the copper plate 1 in the planar direction becomes narrower toward the inner diameter, but as shown in FIG. 4, it is made wider toward the inner diameter to suppress an increase in current density.

FIG. 5 is a partial sectional view of an alternating current generator using the flat coil described above. In FIG. 5, ■ is a steel plate, and 2a is an insulating portion, which together form a flat coil. 4 is a connection terminal, 5 is a connector, and 6 is a shaft rotatably supported by bearings 7a and 7b.

8a, 8b are rotors fixed to the shaft 6, 9a, 9
b is a permanent magnet incorporated in the rotors 8a and 8b, 10a,
10b is a housing, and 11 is a well-known silice bridge that rectifies alternating current.

Then, along the shape of the flat coil that forms the armature,
The side end surfaces 9a1°9b+ of the permanent magnets 9a, 9b are also tapered so that the air gap in the magnetic circuit is minimized.

In this alternator, due to the rotation of the shaft 6 and magnets 9a and 9b, the copper plate l of the flat coil is connected to the magnet 9a.

It intersects with the field magnetic flux from 9b to generate a three-phase AC voltage in the flat coil, which is converted to a DC voltage of a predetermined voltage by a thyristor bridge and output.

In such generators, the temperature of the flat coil tends to rise as the output increases, but in the flat coil described above, it is necessary to increase the thickness of the coil in the axial direction at the inner diameter part of the coil where heat is most likely to accumulate. This improves cooling performance by dispersing heat that tends to accumulate in the inner diameter portion of the coil throughout the flat coil. In this way, it is possible to increase output and improve efficiency without significantly increasing the weight and size of the flat coil.

An object of the present invention is to provide a method for effectively manufacturing a flat coil in which the thickness of the inner diameter portion is increased, and an embodiment shown in the drawings will be described below.

First, a flat copper plate 18 having a certain thickness to is prepared, and in the first step, the thickness t is adjusted as shown in FIG.

Drill a reference hole 20 for the knocking press in the copper plate of
In the step, the slits 21 are punched out using a knocking press as shown in FIG. 7. In the third step, the copper plate after the slit punching process is annealed at 500° C. for 21 hours. In the fourth step, the annealed copper plate is crushed, and this is done by crushing the copper plate with the plate thickness to, slit outer diameter D1, and slit inner diameter D2 as shown in Figures 8 and 9 (a) and (b + Figure 9). As shown in Figure 10 (al, (bl), the plate thickness to of the inner diameter part is larger than the plate thickness t1 of the outer diameter part, and the slit outer diameter is DI'
, the slit inner diameter is shaped to be D2'. Next, this is punched out to obtain a coil wire having the shape shown in FIGS. 3 and 4, and a flat coil as shown in FIGS. 1 and 2 can be manufactured.

In addition, in the method for manufacturing a flat coil according to the present invention,
The third step of annealing may be omitted.

Further, the crushing process in the fourth step may be performed before the slit cutting process in the second process.゛As mentioned above, in the method for manufacturing a flat coil according to the present invention, there are a step of drilling a reference hole for a knocking press in a copper plate of a certain thickness, a step of cutting a slit using a knocking press, and a step of making a slit in a copper plate of a certain thickness. Since the method includes the step of crushing the steel plate so that the steel plate becomes thinner in the outer diameter direction, a flat coil with an increased plate thickness at the inner diameter portion can be manufactured economically through a simple process. is large.

[Brief explanation of drawings]

FIG. 1 is a plan view showing an example of a flat coil manufactured by an example of the method for manufacturing a flat coil according to the present invention;
Fig. 2 is an enlarged cross-sectional view taken along arrow A-A shown in Fig. 1; Fig. 3 is a plan view showing one of the coil strands of the coil shown in Fig. 1; and Fig. 4 is a view shown in Fig. 3. Right side view of the wire part, Figure 5 is the first
A partial sectional view of a generator using the illustrated coil, FIGS. 6 to 10 (al, (bl) are schematic diagrams showing the manufacturing process of an embodiment of the method for manufacturing a flat coil according to the present invention,
fal is a plan view, and (b) is a right side view. 1... Copper plate (conductor), 1c... First ineffective part,
1b... Effective part, 1e... Second ineffective part, 2
...Insulating plate, 3...Ceramic adhesive, to...
Thickness of copper plate. Representative Patent Attorney Takashi Okabe Fig. 1 Fig. 2 Fig. 5 Fig. 1- Go Fig. 6 Fig. 7 Fig. 1 Fig. 8 1 (a) Hole No. 105 (b) Ru (b)

Claims (1)

[Claims] The process includes the steps of drilling a standard hole for a knocking press in a copper plate of a constant thickness, cutting a slit using a knocking press, and crushing the copper plate so that the thickness of the copper plate becomes thinner in the outer diameter direction. A method for manufacturing a flat coil characterized by: