JPS6226260B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a coil assembly for a rotating device, and for obtaining a highly accurate coil assembly by accurately positioning the relative positions of adjacent plate coils. An object of the present invention is to provide a method for manufacturing a coil assembly.

For a coil assembly used in a coreless (iron lossless) motor such as a Hall element motor, for example, in the case of a motor with a 6-pole rotor, 12 hexagonal coils with a relatively small number of turns are used, and adjacent coils are partially connected. There are coils formed into a cylindrical shape by overlapping them, for example, four fan-shaped coils with a relatively large number of turns, or rectangular coils formed into a planar circular shape without partially overlapping each other.

Here, the reason why a hexagonal coil is used in a coil assembly in which adjacent coils are overlapped is that by using a hexagonal coil, the thickness of two coil layers can be maintained approximately uniformly in the circumference after assembly. However, if a rectangular coil is used, there will be three layers at the end of the coil and two layers at the center of the coil, making it impossible to maintain a uniform coil thickness over the circumference, resulting in a decrease in torque. However, the coil assembly of the hexagonal coil used in the conventional coreless motor is, for example, a 6-pole, 2-phase type, which requires 12 coils and has a relatively low torque.

Therefore, it is desirable to have a coil assembly that can obtain relatively large torque with a small number of coils, such as the above-mentioned conventional coil assembly using fan-shaped coils or rectangular coils. For example, it is conceivable to form four rectangular coils with a relatively large number of turns into a cylindrical shape without partially overlapping each other.

When forming such a rectangular coil into a cylindrical shape without partially overlapping, for example, use a cylindrical jig with a movable pin installed inside, and insert the central hole of the rectangular coil into both ends of the movable pin. One possible method is to appropriately displace the movable pin and find a position where a plurality of coils are aligned in a cylindrical shape. However, this method is inefficient, there is a risk of damaging the coil due to the movable pin, and furthermore, after positioning the coil in a cylindrical shape, when sealing it with a mold, the lead wire of the coil is There are problems such as the need to provide a groove in the mold to allow it to escape from the mold.

It is also possible to use the conventional method called the replacement piece method, but this method uses a large number of metal molds with movable pins as described above, which not only makes it impossible to manufacture at low cost, but also makes it difficult to mass produce. This method has the same drawbacks as the above method, such as being inefficient.

The manufacturing method of the present invention eliminates the above-mentioned drawbacks, and an embodiment thereof will be described below with reference to the drawings.

During manufacturing, first, a square hole 1a is provided in the center as shown in FIG.
Four flat rectangular coils 1 (1 ₁ to 1 ₄ ) having the shape b are prepared for each motor, while the coils 1 in FIG.
A synthetic resin preform 2 as shown in B is prepared. Note that the number of turns of the coil 1 is larger than the number of turns of the hexagonal coil. Preformed product 2 is ring part 2a
Four pillars ₂₁ to ₂₄ are erected at equal intervals on the top, and leg parts _2b1 to _2b4 are provided below the ring part 2a corresponding to the pillars ₂₁ to ₂₄ . 2 ₁ ~ 2
Projections 2 1 ′ to _{2 4} ′, which are slightly larger than the square holes 1a of the coils _{1 1} to 1 ₄ , are provided approximately at the center of the outer circumferential side of the coils ₄ . The struts 2 ₁ to 2 ₄ are provided in the ring portion 2 a with a relatively small area, and are formed so as to be relatively easily broken and separated from the ring portion 2 a by pressure in the direction of the arrow.

_Here , _{the square holes 1a of the coils 11 to 14 shown in} FIG. Post 2 with glue
₁ to ₂₄ temporarily as shown in FIG. Next, the legs 2b ₁ to 2b ₄ of the pillars 2 1 _to 2 ₄ are fitted into holes provided at predetermined positions of the printed circuit board 3 on which the speed detection coil 3a is printed.
The lead wires of the coils 1 ₁ to 1 ₄ are soldered to terminals provided on the back surface of the printed circuit board 3. On this occasion,
The pillars ₂₁ to ₂₄ ensure the positioning of the coils ₁₁ to ₁₄ , and there is no need for special positioning operations as in the prior art.

Next, a cylindrical mold (not shown) having a resin pouring portion having a width substantially equal to the thickness of the coils 1 ₁ to 1 ₄ as shown in FIG. 3 is prepared. This mold has a hole for relative positioning of the substrate and the cylindrical part, a mounting hole, and a hole for forming a position detection element pedestal at predetermined positions. The coils 1 ₁ to 1 ₄ are fitted into the cylindrical resin pouring portion of this mold, and the substrate-cylindrical portion relative positioning hole and the substrate 3 are fitted.
Adjust the relative position with the resin and pour the resin into the resin pouring section.

As a result, as shown in FIGS. 4A and 4B, the coils ₁₁ to ₁₄ are all continuously molded into a cylindrical shape with the cylindrical wall portion 4a, while the substrate 3 is placed below the cylindrical wall portion 4a. A base portion 4b having a central hole 4b' is formed by partially molding. Further, position detection element pedestals 4c ₂ and 4c ₃ are formed on the outer peripheral side corresponding to the coils 1 ₂ and 1 ₃ . 4d is a hole used for relative positioning of the substrate and the cylindrical portion, and 4e is a motor mounting hole. At this time, since the mold is provided with a hole for relative positioning of the substrate and the cylindrical part, the coils 1 ₂ , 1
₃ and the position detection element pedestals 4c ₂ and 4c ₃ can be accurately positioned, and the cylindrical wall portion 4a and the substrate 3 can be accurately formed without causing eccentricity. In addition,
Due to the high temperature during this resin molding, the coils 1 ₁ to 1
₄ and the struts 2 ₁ to 2 ₄ are dissolved.

After the synthetic resin of the cylindrical wall portion 4a, the base portion 4b, and the position detecting element holders 4c ₂ and 4c ₃ as shown in FIGS. 4A and B have sufficiently cooled, Push the protrusions 2 ₁ ′ to 2 ₄ ′ of 2 ₁ to _{2 4} with appropriate pressure in the direction of the arrow by hand or with a press machine, etc. to break the struts 2 ₁ to 2 ₄ from their roots, and separate them from the ring portion 2 a. Separate. When the separated struts ₂₁ to ₂₄ are collected, a motor stator as shown in FIGS. 5A and 5B is completed.

Here, let us consider the torque produced by the conventional hexagonal coil assembly and the torque produced by the rectangular coil assembly according to the present invention.

T ₁ : Torque of rectangular coil T ₂ : Torque of hexagonal coil L ₁ : Average circumference of rectangular coil L ₂ : Average circumference of hexagonal coil K〓 _g : Effective magnetic flux linkage coefficient of coil φ _gs1 : Rectangular coil Effective magnetic flux linkage φ _gs2 : Effective magnetic flux linkage of the hexagonal coil is expressed as T ₁ /T ₂ = K〓 _g √2 ₂ 3 ₁ K〓 _g = φ _gs1 /φ _gs2 2 If both heights are the same,
T ₁ /T ₂ becomes 1.3. Therefore, the coil assembly of the present invention requires a smaller number of coils than the conventional coil assembly using hexagonal coils, and can obtain 30% more torque.

Note that the method for manufacturing a coil assembly according to the present invention and its manufacturing method are not limited to only motors, and can be similarly applied to, for example, generators.

As described above, the method for manufacturing a coil assembly for a rotating device according to the present invention includes erecting a plurality of supports for holding the coil winding frame on one side of the annular part in a direction perpendicular to the radial direction of the annular part, and on the other side. Using a preformed product, each of which has a plurality of legs erected to connect and fix a printed circuit board in correspondence with the pillars, temporarily holds a plate-shaped coil on each of the plurality of pillars, and attaches the printed circuit board to the legs. and connect the coil terminals of the plate-shaped coils to the printed circuit board, and at least the spaces between adjacent plate-shaped coils, excluding the plurality of supports, are molded with resin to form a cylindrical coil body and printed. Since the substrate is integrally formed with the leg portions, and after the resin has cooled, only the plurality of support portions are cut out from the annular portion toward the center, the relative positions of the coils are necessarily accurately positioned and movable. It is more efficient and accurate than the conventional method of determining the relative position of the coils using pins, and
There is no risk of damaging the coil, and there is no need to use a special metal mold with movable pins as in the replacement piece method, so it can be manufactured at low cost and can be mass-produced.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a rectangular coil used in the method of manufacturing a coil assembly according to the present invention, FIGS. 5A and 5B are diagrams for explaining each manufacturing process of the method of the present invention. 1 ₁ - 1 ₄ ... Flat rectangular coil, 1a ... Square hole, 2 ... Preformed product, 2 ₁ - 2 ₄ ... Support column, 2
₁ ′ to 2 ₄ ′...Protrusion part, 2a... Ring part, 2b ₁ to 2b ₄
...Legs, 3...Printed circuit board, 4a...Cylindrical wall, 4b...Base.

Claims (1)

[Claims] 1. On one side of the annular part, a plurality of pillars for holding the coil winding frame are erected in a direction perpendicular to the radial direction of the annular part, and on the other side, a plurality of legs for connecting and fixing a printed circuit board are provided in correspondence with the pillars. A plate-shaped coil is temporarily held on each of the plurality of supports using preformed products that are erected, and a printed circuit board is attached to the legs, and the coil terminal of the plate-shaped coil is connected to the printed circuit board. A cylindrical coil body is formed by molding resin between at least the adjacent plate coils except for the plurality of supports, and a printed circuit board is integrally formed with the legs, and after the resin has cooled, the resin is molded. 1. A method of manufacturing a coil assembly for a rotating device, characterized in that only a plurality of strut portions are cut away from the annular portion toward the center.