JPS6032551A - Manufacture of sheet for coil - Google Patents

Abstract

PURPOSE:To improve the arraying accuracy of strands in a sheet widthwise direction by aligning many sheet strands on a base, alinging strands in a slot formed between the sheet strands thereon, and pressure deforming them. CONSTITUTION:Strands 27 are densely aligned between a pair of width restricting guides 26 on the upper surface of a base 25. Then, round strands 29 are then inserted into a slot 28 formed between the adjacent strangds 27. The strands 29 are accurately aligned in the positional accuracy of the strands 27 of lower different sectional shapes. The assembly of the strands 27, 29 is deformed by a roller 30, thereby obtaining a coil sheet 31 in which the strands 27, 29 are aligned without gap.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field] The present invention relates to a method of manufacturing a coil sheet used for manufacturing a coreless armature.

[Background technology]

The manufacturing principle of a conventional iron core armature will be explained with reference to FIG. That is, as shown in Figure 11 and Figure 1 tBl, two cylinders 2 and 2' each formed by arranging a large number of wires 1..., 1'... in the axial direction are prepared, and these cylinders 2 and 2' are each prepared. The number of tension lines 1..., 1'... of both cylinders 2.2' is set to be the same in advance (in the figure, each number is 3i-3).
i'~10i -10i' and 3o-3o'~10o
-10 (total of 8 each of i'). Next, one cylinder 2t
[Twist in the forward direction as shown in Figure 1 tcI, and further twist the other cylindrical ring in the opposite direction as shown in Figure 1 (1) 1,
They form torsion cylinders 11 and 12, respectively. Then, the first
As shown in Figure tEl iC, twist cylinder 11 and twist cylinder 1
Penetrate within 2. In this case, the corresponding strands 1 of the inner and outer layers
．． 1', so that each element wire 1, 1' becomes one wire when combined, so that at one end of both cylinders 11 and 12, elements whose inner and outer layers correspond to each other are connected. The wires (for example, 3° and 3i) are arranged facing each other, and at the other end of the tube, the strands of either the inner or outer layer are arranged so that they are shifted by one (for example, 3°' and 4i'). Cylinder 11
．． 12, a coil unit f is created. Finally, the strands 1°1' of the inner and outer layers corresponding in the radial direction on the torsion circular surface 11.12 are connected at both cylindrical ends to form a coil loop (-
9゜'-+10i'→10i-+10o→10゜'→：
ui'→3I→3゜-su3゜'-+4i'=41→4o
-+4o'-+ 5 i'-+) to complete Muteshintun Isogo.

Next, the detailed method of making bonds by Muteshin Shokiko will be explained using Fig. 2. That is, as shown in FIG. 2 IAI,
The inner layer 15 is formed by winding the sheet 13 in which a large number of strands of wire are arranged so as not to overlap each other in a spiral manner around the core metal body 14, and then as shown in FIG. The inner layer 1 is a sheet 13 formed from the same number of strands 1 from 2 to 2.
5 to form an outer layer 17'ff: wound in a spiral in the opposite direction, and cut these inner circular outer layers 15.17r unit coil/I-7 into lengths to form a coil unit, l-18 (Figure 3). At both cylindrical ends of each coil unit V), the corresponding strands 1 and 1 of the inner layer 15 and the outer layer 17 are all jumpered wires 19 (Fig. 4).
and join to complete the naruko formation on the ironless core I. 20 is a wiring connected to the commutator plate.

Does the sheet 13 have a cross-sectional shape as shown in Figure 5? It is manufactured as shown in FIG. That is, all the strands 1 were completely passed through the tooth-shaped guide 1, and the strands 1 were collected by the upper, lower, left, and right loaves 22 and further pressurized to form them. The strand 1 is a 7-ment wire having an insulating film and a thermosetting adhesive film 1b that is softened and bonded with alcohol around the steel part 1a. In the method shown in FIG. 6, after applying alcohol to the wire 1, in order to obtain the sheet size,
It is pressed in the width direction by the left and right loafs 23.

However, there was a problem in that the pressing force from the lateral direction was not transmitted through the center of the sheet 13, and the widthwise alignment accuracy of the strands 13 was not satisfactory in the cross section of the sheet 13 as shown in FIG.

[Purpose of the invention]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a coil sheet that can improve the arrangement accuracy of wires in the sheet width direction.

[Disclosure of the invention]

The method for manufacturing a coil sheet of the present invention involves arranging a large number of sheet wires on a base, arranging the wires on the base in grooves formed between the sheet wires, and deforming them under pressure. This method is used to make a sheet.

An embodiment of this invention is shown in FIG. First, base 25
Strand wires 27 are arranged closely between a pair of width regulating guides 26 on the upper surface (Fig. 8 (A+)). This wire 27 has an irregular cross section with both side surfaces parallel and the upper surface sloped in an inverted V shape. By arranging the strands 27 closely between the width regulating guides 26, it is possible to obtain a fine pi in the sheet width direction.
When such irregular cross-section strands 27 are used, since the same adjacent strands 27 touch on parallel sides, accuracy in the sheet width direction can be achieved even more reliably and easily. Next, a round wire 29 is inserted into the groove 28 formed between the adjacent wires 27 (FIG. 8(B)). The round strands 29 are aligned accurately in accordance with the positional accuracy of the irregular cross-section strands 27 below. lastly,
The collected leaves 9 of these strands 27 and 29 are pressurized with a loaf 30 as shown in FIG.
As shown in FIG. tDI, it is possible to obtain a coil sort 31 in which each of the strands 27 and 29 is in contact with each other without any gaps. The sheet strand 29, which was round, has been deformed into a pentagon, and the sheet 3 has a shape in which strands 27 and 29 having a pentagonal cross-section in an upside-down direction are arranged alternately.
It becomes 1. Pressure is applied by the roller 30 while applying static pressure or vibration. The strands 27 and 29 are continuously fed onto the base 25 and then pressed by rollers 30. Further, the wires 27 and 29 are provided with an insulating film having a bonding layer.

In this way, the sheet 31 can be formed continuously with high alignment accuracy of the tension lines 27 and 29 in the sheet width direction.

Further, the proportion of copper in the cross section of the sheet 31 is large,
Compared to the conventional method of manufacturing a coil by winding all the strands, the wire area factor increases when it is made into a coil.

Incidentally, a round tension wire 32 may be used as the width V of the irregular cross-section strand 27 as shown in FIG.

〔Effect of the invention〕

The method for manufacturing a coiling sheet of the present invention has the effect of improving the arrangement accuracy of the strands in the width direction of the sheet.

[Invention @2] This invention solves the drawbacks of the aa method shown in FIG. 6, and
The objective is to improve the alignment accuracy of the wires in the sheet width direction.

An embodiment of this invention is shown in FIGS. 10 to 14.

The manufacturing equipment will be explained. In the figure, 33 and 34 are a pair of guide rollers installed vertically, each having an annular groove 33a with a width that allows the tension wires 35 and 36 to fit therein.
, 34a is a bare wire 35. :(The depth of the grooves 33a and 34a, which are formed in large numbers at every other bit and the first groove of 6, is deep enough to insert the strands 35 and 36 for 14 minutes.'' The lower guide roller 33 .34 is the groove part 3: (a, 34
The guide loafs 33 and 34 on the second floor are separated from each other by a distance of about half the width under the soil of the tension lines 35 and 36. There is. 38 is a pair of presser rollers arranged in front of the guide rollers 33 and 34.

In such a device, the strands 35 are fed from above into each groove 33a of the upper guide roller 33, and the strands 36 are fed from below each groove 34a Ic of the lower guide roller 34. The wires 35 and 36 are bare copper wires. These strands 35, 36 are drawn out from the front as shown by arrow Q (FIG. 10). A 1c band-shaped insulating film 39 is fed between the upper and lower wires 35 and 36 of the housing. The insulating film 39
As shown in FIG. 3, a fusion layer 39b (
(This is set up.

Grooves 33a and 34 of upper and lower guide rollers 33 and 34
The strands 35 and 36 sent to the guide roller 33°3
4 are combined with each other as shown in FIG. 14 IB+, and are pinched by the upper and lower presser rollers 38 to form the 14th
It comes out in the form of a sheet as shown in Figure + CI. At this time, the insulating film 39 is inserted between the wires 35 and 36. Note that alcohol is applied to the insulating films 35 and 36. As a result, the fusion layer 39b of the insulating layer 39
serves as an adhesive, and each strand 35, 36 becomes a sheet 40 that is bonded to each other.

Although the sheets are manufactured continuously in this manner, the strands 35 and 36 are guided by the grooves 33a and 34a of the guide loaves 33 and 34, so the arrangement accuracy in the width direction of the sheet 40 is very high. Furthermore, since the wires 35 and 36 are bare copper wires, sufficient tension can be applied without worrying about damage to the coating. Also, since bare copper wire is used, the material cost is low.

[Third invention] Conventionally, in order to form a coil tVfc with two or more layers, a method has been adopted in which a thin repeated copper wire is wound many times using a winding machine, and then swaged or the like is performed to form a coil μ shape. Ta. Therefore, there is a problem that the steel loading ratio becomes low. In addition, in the manufacturing method of fully winding the sheet '6 made of tension wire, 4
In order to make a layer of carp, the head must be wound four times, which is time-consuming. Furthermore, since the sheet is manufactured by the manufacturing method shown in FIG. 6, there is a problem in that the alignment accuracy of the strands 1 in the width direction of the sheet is poor as described above.

The purpose of this invention is that the tension line is 21? ! It is an object of the present invention to provide a method for manufacturing a coil sheet in which the wires are arranged in the width direction of the sheet with good precision.

An embodiment of this invention is shown in FIGS. 15 to 18.

2 in the figure, 41 and 42 are grooves 41a on the surface.

A pair of rolling rollers having 42a f. The grooves 41a and 41b of the pair of lobes 41 and 42 are formed so as to face the inter-groove portions of the other a-ra 41 and 42. A comb-shaped guide 43, a round wire introduction guide roller 44, and a pressure roller 45 are installed in this order in front of the rolling rollers 41, 42.

In such an apparatus, when the copper plate 46 is transferred between the rolling loaves 41 and 42, the copper plate 46 is transferred between the rolling rolls 41 and 42.
As shown in FIG. 17, tB+tq, due to the unevenness, it is cut into a large number of rectangular cross-sectional shapes. The wires 47 and 48 are arranged in two rows in a staggered manner.

These strands 47 and 48Vi pass through the comb-shaped guide 43 and are completely separated from each other (@17 (Dl)).
Insert the wires 49 and 50 made of repeated round wires with a fusion film into the gap between f: ($17 diagram (E)), and apply pressure from above F with the pressure roller 45. Pressure is also applied from the right side by a pressure roller (not shown).As a result, the round wires 49 and 50 are deformed, and the fused film is spread in the gap between each of the wires 49a and 50a. (Figure 17 IF
I), rectangular strands 47°48 will also be coated.

In this way, a two-layer sheet 51 is formed, but since the wires 47 and 48 formed by rolling are bare, they can be fully tensioned without worrying about damage to the coating. Therefore, the accuracy of strand arrangement in the width direction of the sheet 51 can be completely improved. In addition, since the copper plate 46 and the wire 49°50 consisting of the coated round wire are used, the elliptical wire m
Sheet s i2 can be suppressed at a lower cost than that using k. In addition, sheet 51rl: Since it is a two-layered sheet, if this is used, a multi-point winding coil can be fully wound,
It can be formed with half the number of turns of a single layer sheet.

2. As shown in FIG. 18, a copper plate 46' having an insulating coating 46a' may be used, but in that case the insulating effect of the sheet will be poor.

FIG. 19P and FIG. 20 show a four-layer ironless coil I formed using the two-layer sheet 51e.

The strands 52 of each layer 55-58 are interconnected by jumper wires 53, 54 to form a loop. Jumper wires 59 and 60 may be provided as shown in FIG.

61 is a commutator connection line.

[Brief explanation of drawings]

Fig. 1 is an explanatory diagram of the principle structure of a conventional ironless armature, Fig. 2 is an explanatory diagram of its specific manufacturing method, Fig. 3 is a perspective view thereof, and Fig. 4 is a partially enlarged perspective view thereof. FIG. 5 is a sectional view of a conventional coil sheet, FIG. 6 is a perspective view showing the manufacturing method thereof, FIG. 7 is a sectional view showing a defective state of the sheet produced by the same manufacturing method, and FIG. A manufacturing process explanatory diagram of the Kazuo example, FIG. 9 is an explanatory diagram of the manufacturing process of another example,
Figure 10 is a side view of the manufacturing apparatus used in the second invention;
Figure 1 is a perspective view of the guide loaf, Figure 12 is a partial sectional view of the guide roller 7, Figure 13 is a perspective view of the insulating film, Figure 14 is an explanatory diagram of the manufacturing process, and Figure 15. 16 is a perspective view of the rolling roller, FIG. 17 is an explanatory diagram of the manufacturing process of the seventh invention, and FIG. 18 is a partial sectional view of the embodiment of the invention. Figure 19 is a perspective view of a four-layer iron core armature, No. 20
The figure is a partial enlarged plan view showing #7 jumper wire connection state #At-, and Fig. 21 is a diamond-shaped example of the jumper wire connection state? FIG. 25...Pace, 26...Width regulation guide, 27...
- Wire with irregular cross section, 28...Groove, 29...Round wire, 30...Roller, 31...Sheet, 32...
・Round strand, copper plate, 47-50... strand ui'! ,y:'t4:''J

Claims (1)

[Claims] 111 A step of arranging a large number of sheet wires in close rows between a pair of width regulating guides on the upper surface of the base, and a step of arranging a large number of sheet wires in close rows on the upper surface of the arranged sheet wires between adjacent sheet wires on the upper surface of the arranged sheet wires. A process of arranging a large number of sheet strands in each of the formed grooves, and processing the sheet strands placed on the upper surface from above to form a diamond shape so that each sheet strand is in contact with each other without any gaps. (2) A method for manufacturing a coil sheet including the step of making a sheet for coils (2) A pair of coil sheets in which a large number of annular grooves into which a part of the sheet wires are fitted are provided at a pitch of every other sheet wire. a step of preparing a device in which guide rollers are arranged side by side with grooves and partition walls between the seven grooves facing each other; and a step of feeding a sheet wire to each groove of both guide loafs, and feeding one of the guide rollers. An insulating sheet having a fusion layer on both sides is fed between the sheet wire and the sheet tension wire of the other guide roller. A method for manufacturing a coil sheet, which includes the steps of: biting the sheet wire through the wire; and applying pressure from both sides of the sheet wire to smooth out unevenness of the sheet wire to produce a coil sheet. (3) The process of cutting a metal plate into two rows of sheet strands in a staggered arrangement by sandwiching the metal plate between a pair of loaves having a large number of grooves that engage with each other, and the process of cutting a metal plate into two rows of sheet strands arranged in a staggered manner, and a sheet strand having an insulating coating between each of the sheet strands in both rows. Manufacture of coil sheets, which includes the process of arranging the wires, and processing the collected sheet wires from both sides to form a rhombus shape so that each sheet element wire is in contact without any gaps to form a coil sheet. Method.