JPS5931293B2 - Manufacturing method of cylindrical element wire for electric motor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a wire for an electric motor, and more particularly to a method of forming a cylindrical element wire from a hollow truncated cone-shaped wire.

Generally, a cylindrical wave-wound ring body is used as a rotor of a coreless morph, a rotor of a throttle motor, and a stator for generating a rotating magnetic field of a brushless morph, such as a Hall motor.

Conventionally, a method called a honeycomb force method is known as a method for manufacturing such a wave-wound ring body.

In this honeycomb force type, high-speed mechanical winding is difficult because the winding is done while suppressing the slippage of the conductor due to tension when folding at the end face.In particular, it is difficult to wind the wire at high speed mechanically, and it is especially difficult to form a wave winding wheel that is long in the axial direction and has a small diameter. In some cases, a hook pin is inserted to prevent the conductor from slipping, which is inefficient.

In addition to this honeycomb force method, there is also a method of mechanical winding diagonally on a non-metallic bobbin, but it is difficult to wind in an aligned manner, and the bobbin has to be thick to withstand the tension of the conductor, resulting in an increased gap or There is a drawback that inactive parts accumulate in some parts.

Conventionally, a printed coil as disclosed in Japanese Patent Application Laid-Open No. 52-20208 has been known as an armature that can reduce the air gap between the stator and rotor. It is said that it is difficult to apply to cylindrical armatures, and when manufacturing cylindrical armatures, the method of mechanically winding the conductor wire is still used. ing.

The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to provide a method for manufacturing a cylindrical element wire for an electric motor, which can increase the current density and reduce the air gap. be.

An embodiment of the present invention will be described below with reference to the drawings.

Figure 1 shows outer diameter gl, inner diameter g2. An annular wire ring with a conductor width B,
Figure 2 shows the large diameter dl.

Small diameter d2. A hollow truncated conical wire ring having an apex angle δ, a conductor width B, and a length R of a generatrix extending from the apex to a large diameter is shown.

Divide the above circular ring or hollow truncated conical ring into an even number of equal parts 2n (n=1゜2.3...) along its circumference, and at the equally divided points, in the case of a circular ring is bent on the surface at a certain angle φ with respect to the radius, or in the case of a hollow truncated conical wire ring at an angle φ with respect to the generatrix, so that the outer surfaces are almost in close contact with each other, and then the adjacent equally divided points By repeatedly bending the wires to the back side and bringing the inner surfaces into substantially close contact with each other, a wire ring having a shape that fits into an imaginary cylinder having a diameter and a height L as shown in FIG. 3 is formed.

FIG. 4 shows the lines and rings in FIG. 3 developed on a plane.

In FIG. 4, l is the length of the chord of a circular ring or a hollow πD truncated conical ring divided into 2B equal parts.

Also, the string n This is the length that the wire ring of l occupies in the virtual cylinder πD.

As mentioned above, in the case of a circular ring, it is bent to the front side or back side at a certain angle φ with respect to the radius, and in the case of a hollow truncated conical ring, with respect to the generatrix, as shown in Figure 3. When we examine the angle between l in Figure 4 and the perpendicular at the point where l touches the circumference of the virtual cylinder, we find that it is as shown in the figure. It can be seen that it has an angle of φ.

Therefore, from Fig. 4, the following relational expression is derived, and the bending angle φ is the diameter of the virtual cylinder, the height L,
It is found from the equal fraction 2n.

Next, in Figure 1, the length l of the chord of the wire wheel divided into 20 equal parts is
is .

Also, as can be seen from Figure 4, L: 1cosφ (2)
Therefore, by substituting this into the above equation, we obtain the following, which is the equation for determining the outer diameter g1 of the annular wire ring.

Since there is a relationship between gl and g2 as g22gl-2B (4), the inner diameter g2 can be determined by determining the conductor width B.
2 can also be found.

Next, in the hollow conical wire ring in FIG. 2, its large diameter d,
1 is.

In addition, in FIG. 5, which shows the hollow truncated conical wire wheel in FIG. 2 developed on a plane, the chord length l of the wire wheel divided into 2B equal parts is as follows.

However, T is the central angle when the above-mentioned hollow truncated circular ring is developed on a plane.

From this equation and equations (2) and (5), is obtained.

By the way, between the apex angle δ in Fig. 2 and the central angle T in Fig. 5, Seki called Since there is a relation, substituting this into the above formula, we get is obtained.

This is the formula for determining the diameter dl of the hollow conical wire ring.

If D is used instead of L in this equation, from Figure 4, Because it is, From this equation, equation (5), and equation (6), − is obtained.

As is clear from FIG. 2, there is a relationship between the large diameter di and the small diameter d2 of the hollow conical wire when the conductor width is B.

Therefore, the small diameter d2 is determined when the conductor width B is determined.

By the way, the formula (7) for determining the diameter dl of the hollow conical wire ring is
Considering the case where δ=180·, dl becomes, which agrees with equation (3) for determining the outer diameter g1 of the circular ring.

Also, in equation (8) for determining the small diameter d2 of the hollow conical wire ring, if we also consider the case of δ = 180°, then d2 = dl-
2B, which also agrees with the formula for calculating the inner diameter of the circular ring.

In this way, in the formula for determining the large diameter dl and small diameter d2 of the hollow truncated conical wire, if δ = 180', it is equal to the formula for determining the outer diameter gl and inner diameter g2 of the circular truncated wire. Equations (7) or (7) o and (8) for the trapezoidal wire include equations (3) and (4) for the toroidal wire as special cases.

Therefore, in this specification and claims, the toroidal wire is an example of a hollow truncated conical wire, so when it is simply described as a hollow truncated conical wire, it includes the toroidal wire. shall be held.

As described above, in this invention, the cylindrical element wire ring is formed by simply bending the hollow truncated conical wire ring around which the conducting wires are wound in an aligned manner. There is no spatial waste, and the current density can be increased.

Further, the cylindrical element wire of the present invention can be formed sufficiently thin, and the armature in which it is combined can also be made thin.

Therefore, the air gap between the rotor and stator of the electric motor can be made as small as possible, and as a result, a large torque can be obtained.

[Brief explanation of drawings]

Figure 1 shows an annular wire ring, Figure 2 shows a hollow conical wire ring, Figure 3 shows a cylindrical element wire formed from a circular ring or a hollow conical wire ring, and Figure 4 shows a 3rd figure. Developed diagram of , Figure 5 is the second
FIG. gl...outer diameter, g2...inner diameter, l...
・・・The length of the string. dl...Large diameter, d2...Small diameter, δ...
...Apex angle, B...Conductor width, φ...
Bending angle, D...Diameter of virtual cylinder, L...
...Height of the virtual cylinder, T... Central angle of the expanded hollow conical ring.

Claims (1)

[Scope of Claims] 1 A substantially hollow truncated cone-shaped wire ring is formed in which conductive wires are closely wound, and this hollow truncated cone-shaped wire ring is bent along a bending line to form a cylindrical element wire for an electric motor. In the method of forming a ring, the sheath bending line is the circumference of the hollow truncated cone with respect to the generating line connecting the apex of the ring and the equally dividing points defined along the circumference of the ring. A hollow cone that is divided by a bending line by bending a hollow truncated cone-shaped wire in different directions with respect to the plane of the hollow truncated-cone-shaped wire, making equal angles to the direction and along the bending line. The outer surfaces of the trapezoidal wire ring portions are in close contact with each other, and the inner surfaces of the hollow truncated cone wire portions are in approximate contact with each other. A method for forming a cylindrical element wire for an electric motor, characterized in that it is developed into a wave shape. 2 When the diameter of the cylindrical element wire to be formed is D, the length of the cylindrical part is L, the equal dividing point is 2n, and the width and apex angle of the hollow truncated cone-shaped wire are B and δ, respectively. , the bending angle is
A cylinder for an electric motor according to claim 1, characterized in that the diameter of the large diameter portion of the hollow truncated conical wire ring is determined by the following dl, and the diameter of the small diameter portion is determined by the following d2. How to form a shape ring.