JPS6244844B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a multilayer air-core coil, and mainly relates to a method for manufacturing a rotating coil used in a coreless rotating electric machine, in particular, excluding the number of turns in the top layer using self-fused wire. The number of windings in the first layer and the number of windings in other odd-numbered layers are N turns, the number of windings in the second layer and the number of windings in other even-numbered layers are N-1 turns, In this case, the method relates to a method of manufacturing a multilayer air-core coil in which the lower and upper layer windings are wound in alignment in the groove between the windings, and the torque generated by a rotating electric machine using this rotating coil is equalized. In addition, the effective area of the coil is increased to increase the generated torque.

In general, it is desirable for multilayer air-core coils used in ironless rotating electric machines to be as small as possible, and the windings should be sufficiently insulated and have a space equal to the specified coil thickness, so that the windings can be used effectively. It is necessary to

To this end, it is necessary to prevent hollow spaces from occurring in the winding space, which is wound in multiple layers sequentially from the first layer.

However, in the past, a space with a set coil thickness was wound between flanges fixed on both sides of the space in a spiral manner as the first layer at a fixed pitch. When the winding comes into contact with the flange on the winding end side, the wire is wound as a second layer on the winding start side. In this case, the windings transferred from the first layer to the second layer are not wound correctly in the grooves between the windings in the first layer, but are piled up and wound on the final winding of the first layer. Otherwise, the windings may jump over the first groove between the windings of the first layer to the second groove and be wound toward the winding start side. (Figure 5) This jumped winding section causes further jumps during the winding operation from the third layer onwards, creating a hollow space in the coil, making it possible to effectively utilize the space in the thickness of the coil. Therefore, the outer shape of the coil must be non-uniform.

According to our experience, the position of the end of the winding at the beginning of the winding of the first layer of winding and the position of the end of the winding of the winding of the first layer of winding are When the flanges on both sides are in the corresponding position, the winding that has moved to the second layer is correctly positioned in the groove between the windings of the first layer. The windings that are sequentially wound in the first layer and then moved to the third layer are also located in the grooves between the second layer windings, and the fourth and subsequent layer windings are also aligned in the grooves in the same manner as above. It turned out that it was wire wound.

However, since the cross-sectional shape of the insulated winding wire is usually not uniform and there are errors in the wire warp, when trying to wind the desired number of turns within a given coil thickness, it is difficult to wrap the flanges on both sides of the coil. As long as it is fixed as the thickness of It is not a position.

Therefore, the winding that has moved to the second layer is
The layer is stacked on top of the winding at the end of the winding,
Instead of being located in the groove between the windings of the first layer, the wire jumps and is wound in the direction of the winding start of the first layer while being located in the next or subsequent groove.

This means that the wire guide guides the winding wire with a given pitch, and according to the thickness of the coil, even if the end winding of the first layer with a predetermined number of turns reaches the flange on the end winding side. In this case, the wire guide does not change the pitch direction until the predetermined number of turns is reached, and the wires are stacked in contact with the inner wall of the fixed flange. This phenomenon is thought to occur because the number of windings cannot be accommodated.

If the wire diameter of the insulating coated winding wire is uniform, it is possible to wind the wire with a uniform wire diameter the desired number of times within the space of the designed coil thickness.
It would be possible for the winding end positions at the beginning and end of winding to move to the upper layer at corresponding positions on both flanges, but because there are variations in the finished outer diameter of the winding coated with an insulating adhesive, It is considered difficult to wind the first layer of windings a desired number of times within a space with a set coil thickness. It is said that it is difficult to wind the wires in an aligned manner.

Therefore, hollow spaces are created between the windings within the space of the set coil thickness, making it impossible to equalize the torque generated by the rotating electric machine, and making the coil outer shape uneven. I don't get it.

As a result of research in view of the above, the inventor of the present application found that the position of the end of the winding at the beginning of the first layer and the position of the end of the end of the winding at the end of the winding at the corresponding positions of the flanges on both sides are different from those of the second layer. By moving to winding,
Based on the knowledge that the windings on the second and subsequent layers are easily wound in the groove between the upper and lower windings, The present invention has been completed, which allows winding to be carried out in an aligned manner in the grooves of.

Therefore, an object of the present invention is to reduce the number of turns in the top layer of a multilayer air-core coil using self-fused wires, and reduce the number of turns in the first layer and the number of turns in odd-numbered layers to N. The number of windings in the second layer and the number of windings in even-numbered layers are N-1 times, and the windings in the upper and lower layers are aligned with each other in the groove between the windings. Wrapping eliminates hollow spaces in the coil within the space of the coil thickness, equalizes the torque generated by the coil, and increases the effective area of the coil to increase the generated torque. The next object of the present invention is to provide a method for manufacturing an aligned winding multilayer air-core coil using self-fused electric wires that can be manufactured using a simple mechanism. The purpose is to provide a manufacturing method suitable for production.

The above and other objects and features of the present invention can be learned from the following description.

The structure of the present invention will be described in detail with reference to the accompanying drawings showing embodiments.

As shown in the drawing, there is a coil mold base 1 having the same shape as the inner shape of the air-core coil at the center, a winding start slit is provided on one side of the mold base 1, and a fixed flange 2 is formed at right angles to the axial direction. On the other side, the movable flange 3 is slidably and detachably attached to the reel shaft 4 via a screw mechanism or the like, with an interval of at least a predetermined coil thickness at the beginning of winding of the coil mold base 1 of the winding reel 5. A winding wire 6 whose slit is insulated with a thermosetting synthetic resin is guided from a wire source coil 7 to a coil mold table 1 through an appropriate wire guide 8 that operates in reverse at a predetermined pitch. 5
When winding the first layer on the coil mold table 1 by rotating the movable flange 3, the movable flange 3 is moved from the outer end surface of the preset coil thickness to a gap of 20 to 50% of the wire diameter of the winding 6. The winding of the first layer is wound a predetermined N number of times, the variation in the wire diameter is absorbed in the extra gap, and when the winding of the second layer is transferred, synchronization is established. Then, the wire guide 8 is operated to displace at a predetermined pitch in the winding start direction of the first layer (fixed flange side), and while positioning the second layer winding in the groove between the first layer windings. Wound N-1 times,
Next, when the end winding of the second layer transfers to the beginning winding of the third layer, the end winding of the first layer is By positioning the wire guide 8 above the winding at the beginning of winding, and at the same time synchronizing the wire guide 8 and displacing it toward the movable flange 3 at a predetermined pitch,
The third layer winding is placed in the groove between the second layer windings and is wound a predetermined N number of times, and as the winding ends, the wire guide 8 is synchronously displaced toward the fixed flange 2 side. Then move to the first winding of the fourth layer, and wind it N-1 times while correctly positioning it in the groove between the third layer windings according to the winding operation of the second layer, In this way, the desired total number of windings of the coil is reached while winding the upper layers sequentially after the fifth layer, and when the number of windings of the uppermost layer is less than N times, the winding reel 5 After stopping the operation, the winding start and winding end of the coil are appropriately separated, and the movable flange 3 is displaced and fixed at the position of the set coil thickness while heating the coil after winding by applying an appropriate voltage. After the thermosetting synthetic resin coating for the insulation coating of the winding reaches the fusion temperature, the current is cut off and the coil is cooled at room temperature to form a rigid body, and then removed from the coil base mold 1 to obtain the product. shall be taken as a thing.

In the above configuration, the rotational speed of the winding reel 5 can be selected as appropriate depending on the wire diameter of the winding, tensile force, degree of friction of the insulating coating, and other qualities of the winding. The number of wire turns is determined by a separately provided optical sensor and other equipment. When a predetermined number of turns is reached for each layer, the wire guide is reversed, the winding is activated based on a predetermined pitch, and the total number of turns of the coil is synchronized with the winding. The winding reel can be stopped automatically.

In addition, the movable flange attached to the winding reel is
After the coil has been wound the total number of turns, when heating the coil, the coil may be automatically displaced and fixed at a position of a predetermined thickness using an appropriate jig. (However, illustrations are omitted.) Since the invention of the present application has the above-mentioned configuration, the movable flanges of the first layer of winding are set in advance at intervals of 20 to 50% of the wire diameter than the winding width. Because the wire is temporarily positioned and wound, the number of windings of the first layer of wire does not result in excess winding between both flanges. When transferring, the windings are reliably positioned in the grooves between the windings in the first layer, and the windings in the third and subsequent layers are also positioned in the grooves between the upper and lower layer windings. It can be wound in alignment without slips or jumps.

Therefore, since no hollow space is created in the coil, it is possible to equalize the generated torque, increase the effective area of the coil, and increase the generated torque. Therefore, this invention has industrial effects such as improving the connection state with the equipment to which the coil is attached.

[Brief explanation of the drawing]

In the accompanying drawings showing the embodiment, FIG. 1 is a partially cutaway front view showing the state of the windings in the multilayer winding on the winding reel, and FIG. 2 is a cross-sectional view taken along line A-A in FIG. 1. , FIG. 3 is an enlarged sectional view of the insulated wire, FIG. 4 is a partially cutaway enlarged longitudinal sectional view of the same, and FIG. 5 is a partially cutaway front reference view showing a state in which the winding has been jumped.

Claims (1)

[Claims] 1. A fixed flange is disposed on one side of the mold base that forms the inner diameter of the coil in the center, and a movable flange is disassembled on the other side of the mold base, and a mold base is placed between the temporarily positioned flanges. , the first layer and the odd-numbered layers are wound with an insulating coated wire of thermosetting synthetic resin N times, and the second layer and the even-numbered layers are wound with N-1 times,
A method for manufacturing a multilayer air-core coil, comprising melting and forming a coil in a predetermined shape by heating the windings by applying electricity and adjusting the position of a movable flange.