JPS60216746A - Manufacture of cylindrical armature winding - Google Patents

Abstract

PURPOSE:To accurately finish a cylindrical armature winding by forming a boat- shaped strip coil of aligned coils of slender parallelogram shape, and forming a cylindrical winding of a plate-shaped spiral coil bent spirally from the strip coil, thereby reducing the number of connecting steps. CONSTITUTION:A manufacturing method of a cylindrical armature winding includes three steps of shaping a strip coil 23, manufacturing a spiral coil 24 and finishing to a cylindrical winding. The coil 23 is formed of a plurality of element coils having slender parallelogram shape, continuously shaped and disposed on a flat surface, and secured to form a slender boat-shape flat coil. After the coil 23 is spirally bent from a spiral coil 24 by a gauge 54, it is shaped in a flat plate shape. Further, it is finished to a cylindrical winding by winding the coil 24 in a cylindrical winding core so that the upper and lower ends of the coil are superposed, secured to each other, and finished in a winding having uniform thickness.

Description

[Detailed Description of the Invention] [Technical Field of the Invention] The present invention relates to an armature winding for a servo motor, and in particular, it has been recently developed to replace the DC servo motor, which has traditionally been widely used to drive robots and various labor-saving devices. A cylindrical electric machine pre-winding a suitable for brushless motors whose application is increasing.
(hereinafter abbreviated as cylindrical winding).

[Background technology of the invention]

Conventionally, in order to improve the control performance of servo motors, configuration methods incorporating cylindrical windings, such as those found in so-called cup motors, have been implemented. For similar reasons, it is obvious that cylindrical winding is also suitable for brushless motors.

However, and (to target the brushless motor'# force also fp player big capital WL middleman N I Haku X1 inato turtle, -shi fu,
It is surmised that the r-■meden-n1 brushless motor with cylindrical winding is mainly manufactured using a conventional method developed for DC servo motors.

The main methods of manufacturing these conventional cylindrical windings are as follows.

Method a: 19286 Japanese Patent Publication No. 47-19286 A coil in which the windings are fixed with adhesive. Method b: 44362 Japanese Patent Publication No. 53-44362 Cylindrical coil for electric machines and its manufacturing method C method and its manufacturing method method d: Japanese Patent Publication No. 55-43347. Method a of manufacturing ironless cylindrical armature coils for rotating machines: Japanese Patent Publication No. 56-36656. Method a of manufacturing thin-walled coils for electrical machinery. Cylindrical winding is achieved by continuously winding the coils uniformly around the outer circumference of the frame, including the end faces as well as the cylindrical surface, with the connecting terminals exposed, and sequentially fixing the coils with contact adhesive applied to the conductor. This is a method of forming lines.

In the b method, a coil with a diamond-shaped outline is wound continuously with the connection terminals exposed, and the diagonal ridges of the diamond are displaced in the opposite direction to make it flat, and then this is made into a cylindrical shape. This is a method of bending and fixing to form a cylindrical winding.

In method a, a thin cylindrical annular coil is made, and every half circumference of the coil is bent diagonally and in the opposite direction to form an inclined cylindrical unit honeycomb coil. This is a method in which a plurality of unit honeycomb coils are assembled around the outer periphery of a cylindrical frame while being shifted in phase, and the coils are further fixed together to form a cylindrical winding.

In the d method, a thin, approximately cylindrical coil is wound around a band-shaped area surrounded by a coil holder on the outer periphery of a winding frame, and then the coil holder is alternately wound in the axial direction while allowing the winding frame to contract in the radial direction. Even on the opposite side [2.Furthermore, install a coil deformed in a zigzag shape by fixing the coils together.Then, using this zigzag coil as a unit coil, put multiple unit coils on another frame with different phases. In this method, the wires are assembled together and then fixed together to form a cylindrical winding.

Method a includes a method of winding the coil while protruding the connection terminal around the outer periphery of the winding frame that matches the outline of the coil, and f) a means of feeding the coil into the gap between the winding frame and the coil. By mechanically linking four means: a means for supplying the double-sided adhesive tape to the inside of the coil σ] and a means for rotating the tape and the winding relative to the winding frame, the interlayer This is a method in which a two-layer plate-shaped winding is made that is attached with double-sided adhesive tape, and this is further wound and fixed onto another frame to form a cylindrical winding.

[Problems with background technology]

The above conventional method is clearly related to I/C and PL type windings in terms of use, purpose, shape, and function, so it is possible to apply it, but it is applicable to cylindrical coils for brushless motors. This is by no means a satisfactory method for manufacturing windings, and rather leaves room for significant improvement.

The reason for this is, as is well known, the normal DC servo motor,
-++ ,, +-W+ ---I-X turret +/◆-i It adopts an electromagnetic structure in the form of a dark nail analysis, and is configured with a commutator on the rotor. This is because the main body of the brushless motor is a permanent magnet type synchronous machine itself, and has a rotating field type electromagnetic structure, and the problem is due to the difference in type and structure between the two.

Specifically, the following two problems can be pointed out when the conventional method is used to manufacture a cylindrical winding for a brushless motor.

(7) Connection problems The stator windings of ordinary small AC motors are usually wound in a so-called continuous winding method for each phase winding. By omitting the connections between the two, this effect is utilized to reduce manufacturing man-hours.

On the other hand, when constructing a cylindrical winding in the stator or armature using the conventional method in a brushless motor, which can also be said to be a type of small AC motor, it is no longer necessary because it is not equipped with a viscosity coil. Even though there is no
Since the group coils are connected individually, there is an unavoidable disadvantage in terms of the number of connection steps compared to the case of continuous winding described above.

To explain this situation in detail, we will explain the 6-phase multi-pole (number of poles P, P groups 2, 4, 6, 8, etc.) adopted in the armature winding of an AC motor. Table 1 below compares the number of connection terminals between continuous winding and conventional cylindrical winding for band winding.

Table 1 It is immediately clear from Table 1 that the number of connection terminals in the cylindrical winding manufactured by the conventional method is more than twice that of the usual continuous stator winding.

(b) Structural issues When adopting cylindrical windings for the armature of brushless motors, there are structural compatibility issues not only with the windings themselves, but also between the windings and other components in relation to the motor assembly conditions. It is essential. The following two adaptability can be cited as specific requirements.

■ Adaptability of the winding itself The structure of the cylindrical winding itself is simple, the arrangement of each coil is well-arranged, and it can be finished with high precision; There should be no negative impact on subsequent processes or on the motor assembly structure. In particular, in the internal rotor type motor structure that is common in small AC motors, it is easy to install the winding around the inner circumference of the stator core, and it is also easy to assemble the stator and rotor in the subsequent process. thing.

Therefore, the evaluation of the conventional cylindrical winding manufacturing method regarding these two items is summarized as shown in Table 2 below.

Table 2 The reasons for the cases in which adaptability was not recognized or conditions were evaluated as good are generally as follows.

Since the cylindrical winding according to the a method is directly wound over almost the entire outer peripheral surface of the cylinder, it is inappropriate from a geometrical point of view to install it on the inner periphery of the stator core of an internal rotary motor.

In the a method and the d method, a large number of pre-made unit coils are arranged around a cylindrical frame while sequentially shifting the phase and overlapping each other. Since each coil overlaps in a "twill" pattern, it is possible to When the entire coil is formed into a cylindrical shape and fixed, the arrangement of the coils tends to be disordered, which tends to reduce the finishing accuracy.

In method a, if the outline of the coil is made into a diamond shape, the winding will be similar to that in method b, so it has good structural adaptability. However, if the outline of the coil is made into a hexagonal shape, the coil end becomes enlarged, so in order to deal with this, it is necessary to install the windings to the stator core or to install the assembly conditions between the stator and rotor. Due to the need for consideration, an increase in manufacturing man-hours is unavoidable.

Summarizing the study results so far, it can be concluded that among the conventional methods, method a, method a, and method d have problems in both the number of connection terminals of the winding and structural adaptability. Not suitable for manufacturing. On the other hand, method b and method a have good structural adaptability depending on the coil shape, but the number of connection terminals is 6P, which is twice the number of poles in the case of continuous winding of a normal small AC motor, making it difficult to manufacture multi-polar motors. Since this method requires a significant increase in the number of connection steps, there is considerable room for improvement as a manufacturing method for cylindrical windings for brushless motors.

[Purpose of the invention]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a cylindrical winding suitable for an armature for a brushless motor, which has a simple structure, can be finished with high precision, and requires the least number of connection steps. .

[Summary of the invention]

The present invention creates an alignment coil consisting of elongated parallelogram element coils, molds the long coil sides of the alignment coil integrally and flatly to make an elongated boat-shaped band coil, and bends the band coil into a spiral shape. This is a method of manufacturing a cylindrical armature winding in which a plate-shaped spirally folded coil is made and then the spirally folded coil is wound around a winding core by joining both ends to form a cylindrical winding.

[Embodiments of the invention]

First, a structural example of a brushless motor will be explained.

FIG. 1 shows an example of the structure of a brushless motor using cylindrical windings according to the present invention. (a) is a side sectional view, (1
)) represents a half of the front cross-sectional view taken along the line X-XI of (a). As shown in the figure, the brushless motor is composed of a motor section 1 and a rotation detection section 2. The motor section 1 is similar to a normal inner rotor type permanent grinding stone type synchronous machine, and in this example, the field has four poles and the number of armature phases is three. The armature is constructed by constructing a cylindrical winding 22 around the inner periphery of a cylindrical stator core 21.

In addition, 11 is a motor part case, 12 is a bracket, and 13
is the bearing, 14 is the shaft, 15 is the lead wire, 3
1 is a foundation pole, 32 is a rotor yoke, 41 is a light emitting element, 42
43 represents a disc with a slit, and 43 represents a light receiving element.

Next, an example of the structure of a cylindrical winding will be described.

Figure 2 (al) shows the appearance of the cylindrical winding made according to the present invention.
)). As can be easily inferred from the figure, the conductors 221 constituting the cylindrical winding are wound around both the front and back surfaces of the cylinder in a spiral pattern while being aligned, and 222 forms the coil end. are doing.

The conductors on both the front and back layers of the winding are held by adhesive tape 223 sandwiched between them, as shown in FIG. 2 (1).

The present invention uses the following three methods for manufacturing cylindrical windings.
Cylindrical winding wire is manufactured through a process.

In other words, the process is as follows: manufacturing a band coil → manufacturing a spiral folded coil → finishing it into a cylindrical winding.

Below, we will explain the details of each process step by step.

First, the band coil is manufactured as follows.

First, let's talk about the shape of the band coil.

FIG. 3 shows an example of the finished shape of a band coil used for manufacturing a cylindrical winding for a three-lead armature winding. (a) is a plan view and a side sectional view of the long side, (1)) is a side sectional view taken along the Z-Zl line in (a), and CC-) is a side sectional view taken along the U-0' line in (a). FIG.

The band coil 23 consists of a plurality of element coils in the shape of an elongated parallelogram (OABap) as shown by the chain line in the figure.The coils are arranged in continuous alignment on a plane and are fixed to each other. This forms one elongated boat-shaped flat coil, ie, the band coil 23.In this example, each conductor 221 of the coil is fixed with an adhesive tape 223, but the conductor 221 is self-fused. There is no need for this when using a wire connection.

Further, the band coil is divided into the same number of groove coils as the number of phases (three phases) of the cylindrical winding to be manufactured, and taps 224 for connection are provided at the transition points (two places) between the groups.

In other words, the long side of the group coil on the parallelogram (
The two coil sides corresponding to Be, AD) belong to two phase currents that are in phase with each other and have different polarities, for example as shown in U and i in the figure.By adopting such a coil shape, each side of the band coil As shown in the figure, the coil sides are connected to each phase electric current (U in this example) of the multiphase armature winding sequentially along the width direction of the coil.

w, v, u, 'w, v).

Therefore, the winding work of the band coil will be explained.

A band coil is manufactured by winding a conductor around a winding frame 50 as shown in FIGS. 4 and 5 to form a coil, then removing it from the winding frame, and further forming it into a flat shape.

Figure 4 is an assembly diagram showing an example of the winding frame, (a) is a plan view, (
tl) is a side sectional view along V-V+ of Cat, and the fifth
The figure is an exploded view to show the elements of the bobbin. The winding frame 50 consists of three elements: a thin plate 52 and two guides 51 and 53. The plate is used as the winding core of the coil, the concave guide 51 of the two guides is used to guide the coil conductor along two sides ABC of the parallelogram (OABcD), and the convex guide 53 is used to guide the remaining conductor of the coil. This is for keeping warm along two sides.

As is clear from these two figures, the winding frame 50 is constructed by sandwiching a plate 52 between a concave guide 51 and a convex guide 53 to form one body.

The winding work of the band coil is shown in Figure 6 [(a) is a plan view, (1)
) is a side cross-sectional view taken along the w-'w+ri line, the conductor 22 is wound around the two sides of the plate 52. At this time, the conductor 221 is wrapped around the guides 5 and 5.
3 to match the shape of each element coil to a parallelogram (OABOD), and align and fix it on the adhesive tape 223 that has been laid on both sides of the plate in advance, and As mentioned above, at the change of groups, a tap is provided and the wire is wound a predetermined number of times.

The long side (Be, DA) of the parallelogram in Fig. 4(a)
The inclination angle α of the edge surface of the plate with respect to the angle α is made so as to approximately satisfy the following formula.

tanα−L/τ However, τ is the pole part, τ=π, P is the number of poles of the field, D,
L are the diameter and axial length of the cylindrical winding (see FIG. 2), respectively.

Also, it is a good idea to make two uneven guides so that the width between the two long sides of the parallelogram is equal to the width when the conductor wires are lined up for a predetermined number of turns at a pitch that is approximately equal to the diameter of the conductor wire. .

Note that if the angle of the edge surface of the guide is selected to approximately satisfy the following formula, it will be easy to align the conductors during coil winding work.

<ABC county<ODAri 2α Next, we will discuss the fabrication of the spiral folded coil.

Spiral folded coils are made by bending a pre-formed band coil into a spiral shape and then forming it into a flat plate.

As an example, the manufacturing procedure of a spirally folded coil used for manufacturing a four-pole cylindrical winding is shown in Fig. 7 (a1 to (d)). Place the gauge 54 on top of this and sandwich the band coil.The gauge 54 is a thin plate with parallel edges, and the width between the edges is determined by the finish in the axial direction of the cylindrical winding to be manufactured. The length should be approximately equal to L. Also, the edge surface of the gauge should be the same as the strip coil 23.
It is tilted by the angle α mentioned above with respect to the side of the coil.

Then, lift the part of the band coil that is outside the gauge width and bend it along the edge of the gauge as shown in (1)) and (C)K. Next, the band coil is turned over together with the gauge, and after being bent three more times, the gauge is pulled out and formed into a plate shape, resulting in a spirally folded coil as shown in (d).

The number of times the band coil is bent is generally the value obtained by subtracting 1 from the number of poles of the field.

Finally, the finishing method for cylindrical windings will be explained.

The cylindrical winding is made by winding the spiral folded coil around the cylindrical core 55, as shown in Figure 8 (which is a state diagram of winding the spiral folded coil around the core). Finish by molding the top and bottom ends so that they overlap and fixing them together. At this time, as is clear from the figure, the spiral folded coil U
If you first wind the upper part in the diagram and then wrap the lower part, the coil shapes at the upper and lower ends will match each other, so you can create a cylindrical winding with uniform wall thickness. It can be finished into a line.

〔Effect of the invention〕

Thus, according to the present invention, (to) a high-quality cylindrical winding wire with aligned conductors and uniform wall thickness can be manufactured; (a) the number of connection terminals is equal to the number of phase currents, and the number of connection steps is minimized; (a) The coil end is assembled into a slightly protruding shape at one end of the cylinder, so the winding 1fj structure is extremely simple.
It is easy to install on the stator core and assemble the motor. (2) When applied as a Na coil for a brushless motor, the torque ripple is extremely small and excellent control performance can be achieved. The contribution to this field is enormous.

[Brief explanation of the drawing]

FIG. 1 is a structural diagram of a brushless motor formed according to an embodiment of the present invention (al is a side sectional view, (1)) is a
2 is a perspective view of the cylindrical winding of this example, (a) is an external view, (1))
is a detailed view of the part surrounded by the dotted line in (a), Figure 3 is a diagram of the finished shape of the band coil used for manufacturing cylindrical windings, (a) is a plan view and a side sectional view of the long side, (11) is a side sectional view taken along the Z-Z' line in (a), (C) is a side sectional view taken along the El-01 line in (a), and Figure 4 is an example of the winding frame, and (a) is a plan view. , (1
)) is a side sectional view taken along line ■-■1 in (a), Figure 5 is an exploded view showing the elements of the winding frame, and Figure 6 is a state diagram of the band coil winding operation (al is a plan view, (b) is a side cross-sectional view along the W-W+ line, Fig. 7 (a), (t))
(d) is a manufacturing procedure diagram of the spirally folded coil, and FIG. 8 is a diagram showing the state in which the spirally folded coil is wound around the core. DESCRIPTION OF SYMBOLS 1... Motor part, 2... Rotation detection part, 1 work... Motor part case, 12... Platinum), 13... Bearing, 14... Shaft, 15... Lead L 2
1 Stator core, 22... Cylindrical winding, 23... Band coil, 24... Spiral folded coil, 31... Magnetic pole, 3
2... Rotor yoke, 41... Light emitting element, 42...
- Disc with slit, 43... Light receiving element, 5o... Winding frame, 51... Concave guide, 52... Plate, 53...
...Convex guide, 54... Gauge, 55... Winding core, 2
21... Conductor, 222... Coil end, 223...
...Adhesive tape, 224...tap. Applicant's agent Kiyoshi Inomata Figure 1 - Figure 2 (0) 3°9, 2. Tool 1, 2゜Fig. 4 Fig. 7 (Q) Fig. 8

Claims (1)

[Claims] 1. A conductor is attached to a winding frame made up of a thin plate held between two guides, one of which has a concave edge and the other a convex bent edge in a dogleg shape. While guiding along the edges, the conductors are wound a predetermined number of times around both the front and back sides of the plate, with appropriate intermediate taps, to secure the conductors to each other, thereby creating an aligned coil consisting of elongated parallelogram element coils. The long coil sides of the aligned coil removed from the winding frame are integrally and flatly formed so as to be joined along their edges to form a long and thin boat-shaped band coil, and this band coil is formed at a predetermined inclination angle and at a predetermined angle. A cylindrical coil characterized in that the spirally folded coil is wound around a plate-shaped spirally folded core which is formed by spirally bending a number of times, and the two ends are brought together and fixed to form one cylindrical winding. Method of manufacturing armature windings.