JPS6053544B2 - Manufacturing method of flat motor rotor coil - Google Patents

Description

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

Conventionally, in a method for manufacturing a rotor coil for a flat motor of this type, as shown in FIGS. 1 and 2 or 3, a wire 2 is unwound from a wire bobbin 1 under an appropriate tension, and then wound. The wire 2 is wound around the flat winding core 4 of the frame 3 by rotating the winding frame 3 or by rotating the wire inductor 5 to a predetermined number of turns from the inside to the outside in the radial direction of the winding core 4. I am wearing it.

The coil 6 formed in this way as shown in FIG. 4 usually has a large amount of voids between the wires and a space factor of 80% or less.
If applied to a flat motor, a large gap must be provided between the yoke and the magnet in the stator magnetic path, resulting in a decrease in magnetic flux density due to a decrease in permeance, making it extremely inefficient. I couldn't do it. Therefore, in order to improve the space factor of the coil 6,
After winding, the coil 6 is compressed by applying pressure in the thickness direction of the coil 6 so that the wire cross section changes from a circular shape to a rectangular shape. However, in this case, the winding start end 6a of the coil 6 must be pulled out from the inside in the radial direction to the outside.

During compression, the part where the winding start end 6a overlaps with other wires becomes flush with other wire parts, so the winding start end 6a and the parts overlapping with the winding start end 6a are excessively compressed. . As a result, the thickness of the wire was reduced in these parts, making it easy to break, and there was a fear that the wire coating would peel off and cause a thin wire. SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a rotor coil for a flat motor, which eliminates the above-mentioned drawbacks and can prevent breakage and prevent upper rear shorts.

The present invention will be described below with reference to the drawings.

5 to 8 show an embodiment of the present invention, and in this embodiment, a pair of first and second bobbins 11, 1
2 is provided, and when the total length of the wire required to form a coil corresponding to one pole is L and the total number of turns is N, the first
A wire 13 of approximately Ll2 is wound in advance from the bobbin 11 onto the second bobbin 12.

A fan-shaped winding frame 14 is provided when viewed from the end surface, and the winding frame 14 is provided with a pair of end flanges 14a and 14b as well as a center flange 14c.
4c is provided with a groove 14d through which the wire 13 can be inserted. Furthermore, a set of wire inductors 15, 16 is provided for the winding frame 14.
are arranged, and the wire inductors 15 and 16 are connected to the wire 13
is inserted, and fan-shaped wrapping portions 14e and 14f are formed when viewed from the end surface between the end flange 14a and the center flange 14c, as well as between the other end flange 14b and the center flange 14c.
The strands 13 are respectively provided so that the wire 13 can be wound thereon. The center of the wire 13 is passed through the groove 14d of the winding frame 14 as shown in FIG. Rotate first,
The strands 13 of Ll2 on the second bobbins 11 and 12 are
The two-turn winding portions 14e and 14f are wound in two rows as shown in FIG.

As shown in FIG. 7, the strands 13 wound around the winding portions 14e and 14f are impregnated with a solvent having an adhesive function such as acetone and temporarily fixed to form a coil segment. After this the 7th
In the state shown in the figure, for example, the end flange 14a and the winding part 14 are integrated with the winding part 14e, which are provided so as to be able to be combined with each other.
The end flange 14b, which is integral with f, is pulled axially in opposite directions to remove it, and the central flange 14c, which can be divided into two, is pulled radially outward in opposite directions. Remove the coil 17 as shown in FIG. 8.
In this case, since the portion 13a of the wire 13 inserted into the groove 14d is the winding start end, as shown in FIG.
Both the coil end 17 on the first side and the coil end 17 on the second bobbin 12 side are located at the outermost layer of the coil 17. Thereafter, the coil 17 is pressurized to change the cross section of the wire from circular to rectangular to improve the space factor. Even if the coil 17 is sufficiently pressurized and compressed, there is no need to pull out the winding start end from the inside in the radial direction to the outside as in the conventional case, so that no part is compressed excessively and the coil is compressed uniformly. In addition, in the above description, the winding portion 14a
, 14f, it is not necessarily necessary to wind the strands 13 of Ll2 accurately, that is, Nh times, as long as the sum of both coil segments becomes the total length L1, that is, the total number of ampere turns N times. Since each of the coils 17 or 17a configured as described above has a fan shape, the coils 17 or 17a may be arranged in a circular shape depending on the number of poles of the motor, as shown in FIGS. 9 to 13, for example, in a delta connection. The commutator 21 through which the rotating shaft 20 is inserted
The rotor 2
3 is formed.

The rotating shaft 20 of the rotor 23 is supported, for example, by a bearing 26 held by a bowl-shaped yoke 24 via a bearing stand 25 and a bearing 28 held by a flat plate-shaped yoke 27 fixed to the yoke 24. In addition, a magnet 28 is disposed within the yokes 24 and 27, and a brush 31 held on a brush plate 30 to which a terminal 29 is connected is provided so as to be able to contact the commutator 21, thereby completing a flat motor. Ru. As described above, according to the manufacturing method of the present invention, (a) the winding start end of the coil is not pulled out from the inside in the radial direction to the outside, so that the pressing force can be extremely large, preventing breakage and rare shorts. The space factor can be greatly improved without causing any problems.

For example, with a coil formed using wire diameter 0.5T1rIn, the conventional pressurization limit was 3 tons, but it can be increased to 5 tons or more, and as a result, the space factor can be reached to 90% or more. This means that the coil with the same number of turns can be made about 6% thinner than the conventional one, and the gap between the yoke and the magnet can be made smaller, so that the magnetic flux density can be improved by more than 10%.
(b) Two coil division bodies can be made into strands at the same time, and two
There is no need to connect the terminals of the two coil division bodies (c) 2
There is no slack in the coil connecting between the two coil division bodies.
This has the advantage of being easy to manufacture.

[Brief explanation of the drawing]

1 to 4 are explanatory diagrams of a conventional method for manufacturing a rotor coil for a flat motor, and FIGS. 5 to 8 are explanatory diagrams for an embodiment of a method for manufacturing a rotor coil for a flat motor according to the present invention. , FIG. 9 is a partial plan view of the flat motor to which the present invention is applied, FIG. 10 is a side view of the same, FIG. 11 is a perspective view of the same, FIG. 12 is an explanatory view of the same, and FIG. 13 is a half of the same. FIG. 11...First bobbin, 12...Second bobbin, 13...Element wire, 14...Reeling frame, 14a
, 14b... End flange, 14c... Center flange, 14d14e, 14f... Winding part,
15, 16 Takako, 17...Coil, 17'', 1r
... Panting.

Claims (1)

[Scope of Claims] 1. A wire having a first end flange and a second end flange on both end faces, a central flange having a groove in the center for passing the wire through, and having a fan-shaped cross section. A winding frame, a wire inductor for coil winding through which a wire is passed through both sides of the winding frame, and first and second bobbins formed by winding the wire for the coil on the outside of the wire inductor. and fixing the winding frame and rotating the wire inductor to wind a fan-shaped coil on the winding frame, then removing the winding frame from the coil,
A rotor coil for a flat motor, which is characterized in that fan-shaped coil elements are created by pressure molding, and these coil elements are arranged and connected so that the whole forms a circle according to the number of poles of the motor. Production method. 2. The method of manufacturing a flat motor rotor coil according to claim 1, wherein the coil is formed into two divided bodies.