JPS5963957A - Manufacture of coil for coreless motor - Google Patents

Abstract

PURPOSE:To form the upper and lower edges of multiple lamp winding of a coil to be flat by displacing the position of a pawl for engaging and folding a coil wire toward inside as the position approaches the end of winding. CONSTITUTION:The pulse output of an oscillator 22 is inputted to a counter 23, the output pulse of the counter 23 is applied through a driver 24 to a pulse motor 25, and a coil guide arm 48 is rotated and wound. A pulse is sequentially outputted once to the output terminal of a divider of the counter 23 at every ten turns of coils. The output of the output terminal of the divider of the counter 23 is applied through a program switch 28 and a driver 29 to a pulse motor 30. Gears 43, 42 are rotated by the rotation of the motor 30, pawls 38, 39 for engaging and folding the coil wire are moved as the number of turns increases.

Description

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

As a cup-shaped coreless motor, one having a coil structure in which a coil wire is continuously wound obliquely while being reversed at the upper and lower ends of a cylindrical coil is known. (Showa 3rd Publication No. 2151).

FIG. 1 is a perspective view of such a cylindrical coil, and FIG. 2 is a developed view thereof. The coil 1 has a cylindrical shape made of only coil wire and has no coil frame at all. Therefore, the coil 1 can be formed thin and light, and has good starting performance.
There is no torque unevenness, and the gap between the field magnetic circuits can be narrowed to create a strong field space, and the coil can be placed within this space, resulting in large torque and high motor efficiency.

2 is the beginning end of the coil wire, 3 is the end end of the coil wire, 4
is a drawer tap in the middle. As shown in Figure 2, when the coil wire is folded back at point A on the upper edge, it extends diagonally downward along the curve and ends at the lower edge 03, which is 180 degrees away from point A.
It will be looked back at points. On like this.

While repeating the folding of the lower edge alternately, turn to the folding point A.
, by shifting the position of B in the circumferential direction, winding is done,
When this breaking point moves once, a coil and a layer in which each coil wire in the same M diagonal direction is arranged in the same direction are formed. That is, the coil 1 is in a state in which two coil wire layers tl-2 whose inclination directions intersect with each other are stacked. In this case, if the amount of movement of the turning point is reduced as described above, the coil will be wound thickly.

If the coil 1 is left wound, the coil wires will separate from each other, and will deform if external force is applied to it. For this reason, the v-shape is usually formed after the winding is completed.

FIG. 3 is an explanatory diagram of this shaping work. 5 is coil wire 2
The cylindrical core jigs 6 and 7 used for winding are press molds with one side cut into a semi-cylindrical shape. Since so-called cement wire is used as the coil wire, if a solvent is applied or heated during or after winding, the resin film on the outer peripheral surface of the coil wire will soften.

Therefore, immediately after winding, if the pressing die 6.7 is pressed against the winding core jig 5 with the coil 1 in between as shown by the arrow, the coil wires will adhere to each other and become one piece. When such a stamping operation is performed over the entire circumference of the coil 1 while rotating the core jig 5'', the coil 1 becomes a single cylindrical body made of coiled wire.

When the solvent evaporates, the temperature drops and the resin hardens, the coil 1 also solidifies and no longer deforms.

FIG. 4 is a sectional view of a coreless motor incorporating such a coil 1. 10 is an insulating disk fixed to one end of the coil 1, 11 is a commutator fixed to the center of the insulating disk 10, and 12a and 12b are brushes.

Each commutator piece of the commutator 11 has a tap 4 shown in FIG.
, the winding start end 2 and the winding end end 3 are grounded.

Incidentally, the winding start end 2 and the winding end end 3 are commonly connected to form one tap. 13 is a rotor shaft fixed at the center of the insulating disk 10, 14 and 15 are bearings that rotatably support the rotor shaft, and 16 is a cylindrical magnet provided with a gap inside the coil 1. , 17 is a cylindrical yoke provided outside the coil 1 with a distance 'fc between them. Brush 1z&,
When 12b is connected to a power source, a current flows diagonally through the coil 1, and the magnetic flux of the magnet 16 intersects the coil 1 in the radial direction, so torque is generated in the circumferential direction and the rotor shaft 13 rotates in the same direction. do.

Conventionally, when winding a coil, the axial distance between the folding point on the upper edge and the folding point on the lower edge is always equal. There is a problem that the edges protrude in the axial direction at the part where the This is especially true for multi-turn coils. The reason for this is that, as shown in Fig. 6(a), while some of the coil wires 1a in the lower layer have an inclined direction, the other coil wire 1b in the upper layer has a winding diameter of 1 because it bends a lot.
The length of the roll becomes longer. Particularly near the end of the winding, each winding becomes longer because there is no coil wire to be wound on the upper surface. Except for the part near the end of the winding, at least a part of the coil wire is wound on the upper surface of the winding, so that it is pushed toward the winding core jig 5 side and there is no slack, so the wire does not become too long. The coil 1 wound in this way is pressed by the pressing die 6°7 as explained in FIG. The winding diameter becomes small.For this reason, the portion near the end of the 10th turn of the coil protrudes upward and downward from the edge as shown in FIG.

When the green part of the coil protrudes upward and downward in this way, the axial dimension of the coil becomes longer, so the axial length of the motor becomes longer.Also, the length of the coil wire in this part becomes longer. Due to the length, the resistance increases, and there is a problem in that the resistance between the rectifier pieces varies around the entire circumference, causing torque unevenness during one rotation.

The present invention is intended to solve such conventional problems, and aims to provide a method for manufacturing a coil for a coreless motor in which the upper and lower edges of the coil are flat even when the coil is multi-wound. It is.

In order to achieve such an object, in the present invention, the position of the pawl for pulling and folding the coil wire is displaced inward as it approaches the end of winding of the coil, and the amount of the pawl is set arbitrarily by a program. It was designed to do so.

Fig. 7 is a schematic diagram showing one example of a winding machine for carrying out the coil manufacturing method of the present invention, Fig. 8 is a front view of the claw portion, and Fig. 9 is a side view of the same claw portion. -0 In the figure, 20 is the start switch that starts the winding machine, 21 is the start switch 2o, the trigger is 40
22 is a pulse oscillator that is triggered by the 40th pulse and starts oscillating; 23 is a clock input terminal CK; a reset input terminal R2; and a division output terminal Q&, Qb. 70 divider output terminals Q0 to Q, which output only the determined count value. 24 is a driver for driving the pulse motor 25t, 26 is a pulse motor 27
This is a t-driver. 28 has 70 switches, and the input side is the divider output terminal Ql-Q of the counter 23.
yo, respectively, and the output side is commonly connected to a program switch, and 29 is a driver for driving the pulse motor 30t. 31 is a board placed on a stand not shown;
32 is a cylindrical core jig having one end fixed to the substrate 31 with a screw; 33 is a cylindrical core jig having a center hole rotatably supported concentrically on the core 32; 34 is a core jig 33; 35 is a gear fitted to the rotating shaft of the pulse motor 27, 36.37
is a gear for decelerating the rotation of the pulse motor 27. 38 and 39 are pawls, and 40 is a pawl support. The pawl support 4o passes through the substrate 31 and is slidably supported, and one end is rotatably supported by a gear 42. Reference numeral 41 denotes a pawl support, which is slidably supported through the center of the thin core 32, and one end is rotatably supported by a gear 42. The gear 42 meshes with a gear 43 fitted on the rotating shaft of the pulse generator 3o. The actuator 44 attached to the shaft 43 turns off the microswitch 45 at point a, and turns on the microswitch 45 during rotation to point b. - A gear 46 is fitted onto the rotating shaft of the pulse motor 25, and this gear 46 meshes with a gear 47. A winding guide arm 48 is fitted to the gear 4T, and the winding coil 1 is wound around the entire tip of the wire wound around the wire loop 49 along the winding guide arm 48. It is designed to be wound on a core jig.

In the above configuration, first, when the start switch 2° is turned on, the counter 23 is reset and at the same time the pulse generator 21 is triggered to generate 40 pulses. The output of the pulse oscillator 21 enters the microswitch 45.

At the end of the previous winding process, the actuator 44 attached to the gear 43 is in position b, so the microswitch 45 is turned on and the output of the pulse oscillator 21 is sent to the terminal in the opposite direction of the driver 29. input and drive the pulse motor 30 in the opposite direction. Before the pulse oscillator 21 reaches 40 pulses, the actuator 44 attached to the gear 43 moves to position a, and the microswitch 4
5 is turned off, the pulse is supplied to the driver 29, and the pulse motor 30 is stopped. For this, nail 3
8.39 returns to the starting position of the winding. Eventually, the pulse oscillator 21 generates 40 pulses and stops oscillating. For example, 40 pulses are set so that the actuator 44 can sufficiently return to the position a even if the position b is far from the position a. Pulse 'J4 The pulse oscillator 22 is triggered by the 40th pulse generated by the oscillator 21 and starts oscillating. The output of this pulse oscillator 22 is 1
In each coil manufacturing process, the pulse generation period is variably controlled by the user in order to make it easier for the coil winding to be tapped every 100 times. That is, the period is very long at the beginning of the first winding, gradually shortens, and then becomes constant.Then, when the tap drawing operation of the coil is performed, the period gradually becomes longer, and the period becomes the longest.

This operation is repeated every 100 windings. After generating pulses equivalent to 700 windings in one coil manufacturing process, the pulse oscillator 22 stops oscillating. Pulse oscillator 2
2 pulse output is the clock input terminal CK of the counter 23.
When the pulse is inputted, the output pulse of the output terminal Q& of the counter 23 rotates the pulse motor 25 via the driver 24, and the winding guide arm 48 also rotates, thereby unwinding the winding. Number of windings is 10
Divider output of counter 23 for each time ・Output terminal Qi,
A pulse is output only once at the 1M order at -Qy◎. For example, at the first 10th winding, one pulse is output to Q□ 2L, at the next 20th winding, it is output to QB, and at the 700th winding, Q
? One pulse is output at 0. Also, branch output terminal Q
b indicates that the winding core jig 33 is 1 when the winding is repeated 700 times.
The number of frequency division stages is determined so as to rotate. counter 2
The divider output terminals Q0 to Qvo of No. 3 are set to the program switch 28, and the divider output of the switch is applied to the pulse motor 30t through the driver 29 to operate the pulse motor 30t. The rotation of the pulse motor 3o causes the 8iI wheel 43.42 to rotate in the direction of the arrow 38.
39 also moves in the direction of the arrow as the number of windings increases.

The pawls 38 and 39 are formed extending in the circumferential direction of the winding core jig 33, and their tips are in contact with the circumferential surface with slight elasticity. Then, the winding core jig 33 slowly rotates in the direction in which the pawls 38 and 39 extend, as indicated by the arrows in FIGS. 8 and 9.

Further, the coil wire is wound on the circumferential surface of the winding core jig 33 obliquely with respect to its axial direction, as shown by the dashed line in FIG. At this time, the coil wires are alternately hung on the claws 38 and 39 and folded back.

FIG. 10 shows that the coil wire is reflected by the pawl 38 for each winding and is continuously wound obliquely on the circumferential surface of the winding core jig 33, and the coil wire is rotated as the winding core jig 33 rotates. At the same time, the claw 38 is shown to be gradually coming out of the folded portion of the coil wire. Then, the winding core jig 33
The winding ends when the wire completes one rotation. It goes without saying that taps are drawn out at predetermined intervals during the winding.

FIG. 11 is a graph showing the relationship between the movement of the claws 3B and 39 and the rotation angle of the winding core jig 33. As is clear from this graph, the number of coils from the beginning of winding to about half the length of the coil is 38.3.
The amount of displacement at No. 9 is small, and the displacement suddenly increases toward the end. In other words, as it comes to the end of the street, the number 38.3
9 move closer to each other in the axial direction and the distance between them becomes smaller.

As a result, as shown in FIG. 12, the edges of the coil 1 at the end of the winding are shortened. If such a coil 1 is made into a columnar shape as shown in FIG. 5, a short green leaf will extend, and a well-shaped coil 1 with flat edges as shown in FIG. 13 will be obtained.

When manufactured in this way, the coil does not protrude at the upper and lower edges, which prevents the axial dimension from becoming unnecessarily long. Also, the resistance of the coil is almost constant over the entire circumference, which reduces torque unevenness during one rotation. This has the effect that the rotor can rotate smoothly and uniformly.

In addition, at the end of the volume, the pawls 38 and 39 are displaced to the maximum,
At this time, the actuator 44 is at position b. Here, when the actuator 44 is rotated by a predetermined amount from the position a, the switch 45 is turned on. Therefore, the position of b changes according to the set nth maximum displacement amount.

In this way, the program for the displacement amount of the pawl can be arbitrarily set or changed by a simple switch operation of the program switch 2B.

As described above, according to the present invention, there is no protrusion at the edges of the coil, the internal resistance of the coil is all uniform, and a coreless motor can be produced that rotates smoothly without uneven torque.

[Brief explanation of drawings]

Figure 1 is a perspective view of the cylindrical coil, Figure 2 is its expanded view,
Fig. 3 is an explanatory diagram of the shaping operation, Fig. 4 is a sectional view of the coreless motor, Fig. 5 is a front view of a conventional coil, Fig. 6 is a partial sectional view of the coil, and Fig. 7 is a sectional view of the coil of the present invention. A schematic diagram showing an example of a winding machine for carrying out the manufacturing method, Fig. 8 is a front view of the claw part, Fig. 9 is a side view of the same claw part, and Fig. 10 is a diagram showing the winding machine during winding. Front view of the claw part, No. 11
The figure is a graph showing the relationship between the deviation amount of the pawl and the rotation angle of the winding center jig. Figure 12 is a front view of the coil at the end of winding.
Figure 3 is a front view of the coil after it has been molded. 1 working...-coil, 20...-fist start switch, 2
1, 22... Pulse oscillation 4iL23... Φ Counter, 24, 26, 29... Fist driver, 25, 27,
30... Pulse motor, 28... Program switch, 31e... Board, 32... Careful, 33...
... Winding core jig, 34.35, 36, 37, 42, 43
, 46, 47... day wheel, 38, 39... nail,
40゜41・Fist・・Claw supporter, 44・轡・・Actuator, 45・・・Micro switch. Patent applicant: Ohken Seiko Co., Ltd. Representative: Masaki Yamakawa (and one other person) Figure 8 q Figure 10 tl Figure 12 Figure 9 Figure 11 Different version (91 instants, ℃ i7 change-- !shi [13th
figure

Claims (1)

[Claims] A pawl extending in the circumferential direction is placed on the circumferential surface of a cylindrical core, the winding core is rotated in the direction in which the pawl extends, and the coil wire is hooked to the pawl while the winding core rotates once. In a method of manufacturing a coil for a coreless motor in which the coil is folded back and wound continuously diagonally around the winding core, the position of the pawl is shifted inward in the axial direction from the edge of the coil as it approaches the end of the winding. A method for manufacturing a coil for a coreless motor, characterized in that the amount of displacement can be set arbitrarily by a program.