JPS6059823B2 - Manufacturing method for iron-free armature - Google Patents

Description

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

Conventionally, as shown in FIG. 1a, a first sheet-shaped conductive wire bundle 1 is bundled in parallel at equal pitches so as not to overlap.
is spirally wound around a cylindrical core body 2 with a constant radius to form a cylindrical inner layer coil 3, and then a second sheet-shaped conducting wire bundle 4 is wrapped from above the inner layer coil 3 as shown in the figure.
is spirally wound in a reverse spiral direction to form an outer layer coil 5, and both the inner and outer layer coils 3 and 5 are simultaneously cut at regular intervals L, and both conductor bundles 1 and 4 are formed at the end surface 6 of the cut portion. A method has been developed for manufacturing a coreless armature by welding together individual coated conductors 7, 8.

However, in this method, in order to form the inner layer coil 3, a sheet-shaped conducting wire bundle 1 is placed around a cylindrical core body 2 with a constant radius R.
However, when forming the outer layer coil 5, the diameter of the core body 2 is increased by the thickness of the inner layer coil 3, so when the second sheet-shaped conducting wire bundle 4 is wound, the coated conducting wire is 8...8 became impossible to tightly wrap, resulting in a drawback that a gap δ1 was generated as shown in FIGS. 2 and 3. The present invention aims to fill the gap δ1 between the coated conductors 8...8 of the outer coil 5, and to align the pitches of the coated conductors 7, 8 welded to each other in both the inner and outer coils 3, 5. There are things to do. Below, the configuration of the present invention will be explained with reference to the illustrated embodiments.
As shown in Figure a, a first sheet-shaped conducting wire bundle 1 that is bundled in parallel at equal pitches and without overlapping is arranged at a constant radius R.
A cylindrical inner layer coil 3 is formed by spirally winding around the cylindrical core 2, and then a second sheet-shaped conducting wire bundle 4 is reversely wound from above the inner layer coil 3 as shown in FIG. The outer layer coil 5 is formed by spirally winding the inner and outer layer coils 3 and 5, and the inner and outer layer coils 3 and 5 are simultaneously cut at regular intervals L. In the method of manufacturing a coreless armature by welding coated conductors 7 and 8 to each other, as shown in FIG.
The width of the covered conductor 8 forming the conductor bundle 4 of the first conductor bundle 1 is
The radius R of the core 2 is larger than the width of the covered conductor 7 forming the
The length of both the inner and outer coils 3 is set to be longer than the ratio of the sheet thickness t of the first conducting wire bundle 1 to
, 5, the pitches of the coated conductive wires 7, 8 which are welded to each other at the end faces 6 of the cut portions of the conductive wires 7, 5 are made to be the same.

That is, if the sheet thickness of the first sheet-shaped conducting wire bundle 1 forming the inner layer coil 3 is t, and the radius of the cylindrical core 2 around which the inner layer coil 3 is wound is R, then the inner circumference of the inner layer coil 3 is is 2πR, and the outer circumference is 2? Since r(R+t), the sheet width F2 of the second conducting wire bundle 4 forming the outer layer coil 5 should be made t/R times longer than the sheet width e1 of the first conducting wire bundle 1 forming the inner layer coil 3. For example, the outer layer coil 5 can be wound without any gaps, and both the inner layer and the outer layer can be wound. This allows the pitches of the coated conducting wires 7 and 8 of the coils 3 and 5 to be welded to each other to be the same. By the way, in the embodiment of the present invention shown in FIG. The width of each covered conductor 8 forming the first conductor bundle 4 is set to the width of each covered conductor 7 forming the first conductor bundle 1.
However, it is not desirable to use covered conductor wires of different standards for both the inner and outer coils because it increases production costs.

Therefore, in the embodiment of the merged invention shown in FIG.
The conductor bundle 4 is a coated conductor wire 8'' of the same standard as the first conductor bundle 1.
By tilting the individual covered conductor wires 8'' in the width direction of the sheet, the sheet width E2 of the conductor bundle 4 is
The sheet width e1 of the conducting wire bundle 1 is set to be t/R times longer than the sheet width e1 of the conducting wire bundle 1. In this way, it is possible to use coated conductors 7 and 8'' of the same standard for the first and second conductor bundles 1 and 4, so production costs can be reduced.As described above, In the present invention and its combined inventions, the sheet width E2 of the second conducting wire bundle forming the outer layer coil is the sheet width e of the first conducting wire bundle forming the inner layer coil.
Since the length is set to be t/R times longer than 1, there is an advantage that the gap between the coated conductors forming the outer layer coil can be filled, and the coated conductor wires to be welded to each other in both the inner and outer layer coils can be filled. It has the advantage of being able to align the pitches.

In particular, in the embodiment of the combined invention shown in FIG. Since the sheet width of the second conductor bundle is made to be longer than the sheet width of the first conductor bundle by a predetermined length by tilting the conductor wire to can be shared, which has the advantage of reducing production costs. In both cases of FIG. 5 and FIG. 6, it is possible to bond the covered conductive wires together in advance, so there is an advantage that the coil winding operation is easy. However, the common method for bonding coated conductors to each other is to align the coated conductors in a sheet shape using an alignment roll and then bond adjacent coated conductors by applying an adhesive. If the conductor is formed of an insulating film layer applied to the conductor and a thermoplastic resin layer applied to the outer surface of this insulating film layer, the covered conductor wires are aligned in a sheet shape using an alignment roll. There is also a method of bonding the thermoplastic resin layers of adjacent conductive wires by heat welding, and there is also a method of using the above-mentioned adhesive method and heat welding method together to ensure and strengthen the bond.

[Brief explanation of the drawing]

FIGS. 1A and 1B are perspective views showing a conventional method of manufacturing a coreless armature; FIGS. 2 and 3 are enlarged front views of the same main parts;
4 and 5 are enlarged front views of essential parts of a manufacturing method according to an embodiment of the present invention, and FIG. 6 is an enlarged front view of essential parts of a manufacturing method according to an embodiment of the combined invention. Reference numerals 1 and 4 indicate a bundle of sheet-like conductive wires, 2 indicates a cylindrical core, 3 indicates an inner layer coil, 5 indicates an outer layer coil, 6 indicates an end face of a cut portion, and 7 and 8 indicate coated conductive wires.

Claims (1)

[Claims] 1. A cylindrical inner layer coil is created by spirally winding a first sheet-shaped conducting wire bundle bundled in parallel at equal pitches so as not to overlap each other and around a cylindrical core having a constant radius. Further, a second sheet-shaped conducting wire bundle is spirally wound in a reverse spiral direction from above the inner layer coil to form an outer layer coil, and both the inner layer and outer layer coils are simultaneously cut at regular intervals,
In a method for manufacturing a coreless armature by welding individual covered conductors forming both conductor bundles to each other at the end faces of the cut portion, the width of the covered conductors forming the second conductor bundle is set to the width of the first conductor bundle. The coated conductor wire is set to be longer than the width of the coated conductor wire forming the conductor bundle by the ratio of the sheet thickness of the first conductor bundle to the radius of the core body, and is welded to each other at the cut end faces of both the inner and outer coils. A method for manufacturing a iron-free core type armature characterized by aligning the pitches thereof. 2 The first sheet-like conducting wire bundles, which are bundled in parallel at equal pitches and without overlapping, are spirally wound around a cylindrical core with a constant radius to form a cylindrical inner layer coil, and further the inner layer A second sheet-shaped conducting wire bundle is spirally wound in a reverse spiral direction from above the coil to form an outer layer coil, and both the inner and outer layer coils are simultaneously cut at regular intervals,
In a method for manufacturing a coreless armature by welding individual coated conductors forming both conductor bundles to each other at the end face of the cut portion, the coated conductor wires forming the first and second sheet-like conductor bundles are used. By using a conductor with a rectangular cross section, using covered conductors of the same standard for both conductor bundles, and tilting each coated conductor of the second conductor bundle that will become the outer layer coil in the sheet width direction, the sheet width of the conductor bundle can be increased. The width of the sheet is set to be longer than the sheet width of the first conductor bundle by the ratio of the sheet thickness to the radius of the core, so that the pitches of the covered conductors to be welded to each other at the cut end surfaces of both the inner and outer coils are aligned. A manufacturing method for a featured ironless core armature.