JPS5920264B2 - Disc type multilayer armature winding and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a disc-type multilayer armature winding.

Conventionally, a disk-type multilayer armature winding, as seen in so-called printed motors, first consists of a disk-shaped unit coil formed by forming half coils of a predetermined shape radially on both sides of an insulating substrate, for example. Then, the inner ears of the half coils on both sides protruding toward the inner circumference of the insulating substrate are connected to form a one-turn coil, and the outer ears of each half coil protruding toward the outer circumference of the insulating substrate are connected to each other. A predetermined armature circuit is configured by connecting with the outer ear portions of other unit coils.

However, in that case, a plurality of unit coils are stacked so that the connection parts of other unit coils are within an interval equivalent to one pitch between the connection parts of the unit coils, but the connection part of each unit coil is are arranged on a circumferential line of the same diameter, so there are 10 or 12 layers of half-coils, or 5 unit coils.
When attempting to stack the coils in multiple layers such as 6 layers or 6 layers, there is a risk that the connecting portions of other unit coils may come into close contact with each other and cause a short circuit phenomenon.

Furthermore, if the short circuit is prevented by reducing the number of half coils arranged in the circumferential direction in each unit coil, the space factor of the coil as a whole will decrease.

Therefore, in the past, it has been quite troublesome to construct multilayer windings, and few print motors have been proposed that can be driven by a commercial power source of, for example, 100 volts or 200 volts without a transformer.

In view of the above, it is an object of the present invention to provide a disc-type multilayer armature winding which is free from the risk of short-circuit accidents and which allows connection between coils to be carried out by practical arc welding. .

In order to achieve this object, the present invention provides a plurality of flat semi-coils having a predetermined shape on both sides of an insulating sheet such that the connecting portions on the inner circumferential side between the half-coils on both sides are located at approximately the same radius position, and Multiple layers of disk-shaped half-coil assemblies are stacked in the axial direction with an insulating sheet interposed between them, and the connecting portions of the half-coils in each layer are placed at the same radial position. The first and second coil assemblies are arranged symmetrically with an insulating sheet interposed therebetween, and the connecting portions between the two coil assemblies are connected within each coil assembly. Distributed in the circumferential direction at a radial position inside the connection between the half coils on the inner circumference side of the coil assembly or at a radial position outside the connection between the half coils on the outer circumference side of each coil assembly, The method of manufacturing a disc-type multilayer armature winding is characterized in that the connection portion is formed by arc welding.

Next, the present invention will be explained in more detail with reference to the drawings.

The figure shows an example in which half-coil assemblies are stacked in 10 layers, and the steps will be explained below in order.

FIGS. 1, 2, and 3 show three types of coil patterns A, B, and C formed by notching from a thin conductive plate of the order of 0.1 mesh.

Each coil pattern A, B, and C has a central square hole 2 for positioning shown by hatching, and the half coils are removed by notching, and are connected to each other by a connecting part 3 on the inner circumferential side and a connecting part 4 on the outer circumferential side. each several half coils 1
I have 1, 12, and 13.

In each coil pattern, the spacing between individual half-coils is actually rather small, and therefore the number of half-coils is often large. The spacing between the half coils is relatively thick (
, and only two half-coils in each case are representatively shown.

The half coil 11 of coil pattern A has a short inner ear part 11a and a long outer ear part 11b.

The half-coil 12 of coil pattern B has a long inner ear portion 12a and a short outer ear portion 12b.

Furthermore, the half coil 13 of coil pattern C has a short inner ear part 13a and a short outer ear part 13b.

Next, first, as shown in FIGS. 4 and 5, an insulating sheet 1 with a thickness on the order of 0.1 mrti has an inner diameter and an outer diameter such that both the inner and outer ear portions of each coil pattern protrude.
Glue the half coil 11 to the coil pattern on the top surface of 4,
Half coils 13 of coil pattern C are glued to the lower surface, the ears of each half coil are trimmed to a predetermined end position to remove connecting portions 3 and 4, and then surface-to-plane connections are made by arc welding on the inner circumferential side. That is, the inner ear part 1 of the half coils 11 and 13
The first unit coil 15 is constructed by connecting the coils 1a13a to each other by welding.

Connections are indicated by black circles.

Here, a connection method in which the inner ear parts and the outer ear parts of the surface-to-plane connection are connected by TIG welding will be generally described with reference to FIGS. 16 to 18.

First, as shown in FIG. 16, half coils 5a are placed on both sides of an insulating sheet 60.

5b, an ear portion 5c protruding from the edge of the insulating sheet 6;
As shown in FIG. 17, the sd is shaped using a jig 7 to enable welding and to ensure good heat transfer from the ears to the jig 7.

Since the jig 7 is also used as an electrode, it has a high thermal conductivity (,
Moreover, it is made of conductive metal.

A thorium tungsten electrode 9 protruding from the central nozzle hole of the nozzle 8 of the welding machine is set so as to face the end surfaces of the ears 5c and 5d to be welded.

While ejecting inert gas from around the nozzle 8, that is, the electrode 90, a high frequency voltage is applied between the electrode 9 and the jig 7, and a high frequency wave is first applied between the electrode 9 and the ears 5c and 5d.
Next, an arc current is superimposed thereon to weld the two ear parts together while preventing arc breakage.

The heat generated during welding is absorbed by the jig 7, and the ear part 5cy
Instantly performs welding between sd.

In this way, the connecting portion 10 as shown in FIG. 18 can be constructed.

Next, as shown in FIGS. 6 and 7, half coils 13 of coil pattern C are adhered to the upper and lower surfaces of an insulating sheet 16 having the same dimensions as the insulating sheet 14, respectively, and trimmed in the same manner as above. The connecting portions 3 and 4 are removed, and the second unit coil 17 is constructed by connecting surfaces on the inner circumferential side.

Next, as shown in FIGS. 8 and 9, the unit coil 1
A half-coil of coil pattern B is placed on the lower surface of the insulating sheet 18, which has an inner diameter that is equal to or slightly more inward than the connection portion between the inner circumferential sides of the insulating sheet 14 or 17, and an outer diameter that is equal to the insulating sheet 14 or 16. 12 and perform predetermined trimming, the second unit coils 17 are placed on the upper surface of the insulating sheet 18 and are bonded together to form the coil assembly 1.
9.

Next, as shown in FIG. 10 and FIG. After adhering the unit coils 15 to each other and bending the upper outer ears of the unit coils 15 upward at an almost right angle at the outer peripheral edge of the insulating sheet so as not to interfere with the welding work, the half coils on both sides are glued together on the outer peripheral side of the insulating sheet 20. The coil assembly 21 is constructed by connecting the coil assembly 21 simultaneously and on the same plane by the above-mentioned TIG welding.

Two sets of coil assemblies 21 configured as described above are prepared, and as shown in FIG.
The half coils 12 of the coil pattern B bonded to the coil pattern B are arranged symmetrically so that they face each other, and have an inner diameter equal to that of the insulating sheet 18 and an outer diameter equal to or slightly larger than the surface-to-face connection portion on the outer periphery of the insulating sheet 18. They are laminated with an insulating sheet 22 having a diameter interposed therebetween and bonded to each other.

Then, the folded outer ears of the top layer and the bottom layer are returned to their original positions, and the half coils on both sides of the insulating sheet 220 are connected face-to-face on the inner circumferential side, and the half coils on both the upper and lower end faces are interconnected on the outer circumferential side. .

In this way, the disc-shaped multilayer armature winding 23 consisting of ten half-coil layers is completed.

Although one specific example of the present invention has been described above, the dimensions of the inner diameter side or outer diameter side of each insulating sheet are determined according to the insulation strength required for the coil conductor connection portions on both the upper and lower sides,
In addition, the lengths of the ears of the pair of half-coils that are connected to each other in the final process, that is, the inner ears of the two sets of half-coils at the center in the axial direction and the outer ears of the two sets of half-coils on both upper and lower end surfaces, are different from each other. This makes it easier to connect by welding while maintaining a predetermined insulation strength.

In the above embodiment, coil patterns with different lengths for the outer ear part and the inner ear part were created by notching from the beginning, but instead of that, initially both the inner ear part and the outer ear part were made with long lengths. It is also possible to perform notching in common according to the pattern size, and to adjust the notching to a predetermined size during subsequent trimming.

The coil shape, number of laminated layers, and wiring method of the half-coil can be changed in various ways, and accordingly, the way to determine the length of the ear part of each half-coil or the size of each insulating sheet can also be changed in various ways different from the above embodiments. It can be implemented in a certain way.

FIGS. 13 and 14 show such a modification in the case where the number of stacked layers is 12.

In the case shown in Fig. 13, 6 sets of insulating sheets 300 each having a short inner ear portion 1 glued to both sides of the insulating sheet 300 are prepared, and the half coils 1 with short inner ear portions are glued on both sides of the insulating sheet 300. They are laminated with an insulating sheet 32 with a large protruding size interposed therebetween and then bonded to each other.

However, in this case, the insulating sheet 32a at the center in the axial direction has a large outer diameter for the convenience of interconnecting the half-coils on both sides, and the outer diameter of the half-coil 31a in the third layer from each end surface side is made large. The section is similarly long.

In this case as well, the connection portions between the half coils on the outer circumferential side within each of the upper and lower half coil assemblies are on the same plane.

In the one in Figure 14, the long half coil of the outer ear part is 34.35.
are arranged on both end surfaces and in the center, respectively, and the long ears are interconnected on the outer periphery, between both end surfaces and in the center.

In this case, the connecting portions of the half coils on the outer circumferential side of each coil assembly have approximately the same diameter and are on the same plane, and the connecting portions between the coil silk bodies have the same radius and a larger radius than the connecting portions of the half coils. It is on a plane.

In the drawings used for the above explanation, each half coil and insulating sheet are drawn much thicker than they actually are for clarity, but as already mentioned, the individual thickness of these members is 0.1 mm. The order is extremely thin,
Therefore, the thickness of the armature winding in the completed state is only about 2 mm.

That is, →l configured as a so-called axial gap type print motor is shown in FIG. 15.

In Fig. 15, 40 is the output shaft, and the bearing 41.4
It is rotatably supported by brackets 43 and 44 via 2.

Inside the casing constituted by brackets 43 and 44, a disc-shaped armature 45 mainly composed of a disc-shaped multilayer armature winding according to the present invention is attached on the output shaft 40.

A stator magnetic pole 46 made of a permanent magnet is disposed on the bracket 44 so as to face the winding portion of the armature 45 with an axial gap in between.

A brush 47 is also arranged on the bracket 44 so as to be able to come into sliding contact with a commutator piece formed on the inner circumferential side of the armature 450 winding.

Each commutator piece may utilize the inner ear portion of the coil conductor itself constituting the armature winding, or a separate piece electrically connected to each coil may be prepared.

According to the armature winding manufacturing method of the present invention explained above,
By using a combination of half-coils with coil patterns with different lengths of the inner and outer ear parts, connections between half-coils within a coil assembly and between coil assemblies can be easily made by welding, and the number of armature conductors is also reduced. can be significantly increased compared to conventional methods, making it possible to manufacture high-voltage, small-current printed motors that were previously considered impossible.

In the armature winding for high voltage and small current, the thickness of the conductor can be made thin in terms of current capacity, so the thickness of the entire winding does not become particularly thick.

By realizing a high-voltage motor, it will be possible to drive it from a commercial power supply system without a transformer, so the control device can also be downsized, and this coupled with the ability to use small-current control elements. The practical advantages of significantly reducing the size of the device are significant.

It should be noted that the armature winding of the present invention can also be applied to a generator for speed detection, for example, and it is clear that the size of the entire generator can be reduced in that case as well.

[Brief explanation of drawings]

Figures 1, 2, and 3 are diagrams showing three different types of coil patterns, Figures 4, 6, 8, and 10.
Figures 5, 7, 9 and 11 are longitudinal cross-sectional views corresponding to a series of manufacturing steps of the armature winding according to the present invention, respectively. A perspective view of the main parts of the armature winding in each step corresponding to FIGS. 8 and 10,
Figures 13 and 14 are simplified layout diagrams showing examples of wiring configurations different from those in Figures 4 to 12, respectively, and Figure 15 is a Boleyn diagram showing an example of the use of the disc type multilayer armature winding of the present invention. Fig. 16 is a longitudinal sectional view of the two-handed coil to be connected by welding, Fig. 17 is a longitudinal sectional view showing the welding of the ears of a half-coil, and Fig. 18 is a longitudinal sectional view of the half-coil. FIG. 3 is a longitudinal cross-sectional view showing a state in which the ears are connected by welding. A, B, C...Coil pattern, 11, 12° 13-
...half coil, 11a, 11b, 12a, 12b13a
t 13b...Ear part, 14. 16. 18.202
2...Insulating sheet.

Claims (1)

[Claims] 1. A plurality of flat semi-coils of a predetermined shape are formed radially on both sides of an insulating sheet so that the connection parts on the inner peripheral side between the half-coils on both sides are located at approximately the same radial position and distributed in the circumferential direction. A disk-shaped coil assembly is stacked in multiple layers in the axial direction with an insulating sheet interposed between them, and the connection parts on the outer circumferential side of the half coils in each layer are connected at the same radial position so as to be distributed in the circumferential direction. The first and second coil assemblies are arranged symmetrically with an insulating sheet in between, and the connection between these two coil assemblies is the connection between the half coils on the inner circumferential side of each coil assembly. The connecting portions are distributed in the circumferential direction at radial positions inside the half-coil portion or at radial positions outside the connecting portion between the half-coils on the outer circumferential side of each coil assembly, and the connecting portion is formed by arc welding. A method for manufacturing a disc-type multilayer armature winding, characterized by: