KR102242730B1 - Winding coil assembly for brushless motor and Method for manufacturing the coil assembly - Google Patents

Abstract

The present invention relates to a wound coil assembly for a brushless motor and a method for manufacturing the same. The assembly comprises a plurality of unit wound coils which have a rectangular shape with the empty center portion and constitute a cylinder on the whole by being connected laterally to each other in a bent state, wherein the unit wound coil is produced by using a winder to wind a wire and has vertical portions which have a given width and are parallel to one another and the horizontal portions which are formed integrally into the upper end portions and lower end portions of the vertical portions and parallel to one another, and the unit wound coils adjacent to one another are fused by heat to one another while the vertical portions are overlapped. In the wound coil assembly for a brushless motor according to the present invention, the unit wound coils are connected in a circumferential direction to each other to form a shape of a rectangular plate, so a length in a vertical direction perpendicular to the circumferential direction is short, thereby allowing a size of a motor to be reduced, and the number of necessary components are small to allow good assembly and high density of coils, thereby enhancing performance of a motor. In addition, the unit wound coils are bonded by a method of heat fusion, thereby eliminating concerns about deformation or separation by vibration or impact occurring externally and ensuring durability and reliability of product quality.

Description

Winding coil assembly for brushless motor and Method for manufacturing the coil assembly}

The present invention relates to a winding coil embedded in a brushless motor, and more particularly, to a winding coil assembly for a brushless motor and a method of manufacturing a winding coil assembly, which improves the performance of the motor due to high coil density, and has good assembly properties. will be.

Electric motors, which are importantly used in almost all industrial fields, are power generation devices that output rotational torque by externally applied power, and include direct current method, single-phase AC method, and three-phase AC method depending on the power supply method. . Also, depending on the structure and operation, there are geared motors, step motors, servo motors, brush motors, brushless motors, and the like.

The brush motor has a commutator fixed to the rotor and a brush that is elastically connected to the commutator. The disadvantage of brush motors is that the commutator and the brush rub. For example, since the brush is elastically connected to the outer circumferential surface of the commutator rotating at high speed, noise and sparks are inevitably generated, and when the brush is worn to some extent, there is inconvenience such as having to replace the brush.

In contrast, a brushless motor is a motor without a brush, and a built-in magnetic sensor detects the magnetic field of the rotor and transmits a detection signal to the coil of the stator to control the rotation of the motor. Such a brushless motor has a basic configuration of a housing, a rotor installed in the center of the housing, and a stator provided between the rotor and the inner circumferential surface of the housing. Further, the stator includes a metal core and a coil wound around the core.

On the other hand, the brushless motor that is built into the handpiece of the small inner diameter and the elongated shape has a narrow space between the rotor and the inner circumferential surface of the housing, so as a stator, several unit winding coils on a thin curved surface are used in the circumferential direction. An overlapping configuration, such as a winding coil assembly, is used.

However, conventionally, in order to construct the winding coil assembly, a method of inserting unit winding coils one by one has been applied. This assembly method is very cumbersome, and the probability of assembly failure is high because the overlap area between unit winding coils is not constant. In addition, after assembly, it may be short-circuited in severe cases due to movement by vibration or shock transmitted from the outside.

In addition to these methods, there is also a method of separately assembling the winding coil assembly from the outside of the housing and inserting and installing the assembled assembly, but the correct size that can fit and fix the winding coil assembly in the narrow gap between the rotor and the housing. It is not easy to assemble into a and shape, and this also has poor assembly productivity.

Korean Patent Publication No. 10-0942437 (Brushless Motor)

The present invention was created to solve the above problems, and it is possible to further reduce the size of the motor, and to improve the performance of the motor due to the small number of parts, good assembly, and high density of the coil, as well as to prevent vibration or shock from outside. It is an object of the present invention to provide a winding coil assembly for a brushless motor and a method of manufacturing a winding coil assembly without fear of being deformed or separated by it.

The winding coil assembly for a brushless motor of the present invention as a means of solving the problems to achieve the above object takes the form of a square plate with an empty central portion, and is connected in a lateral direction in a bent state to form a cylindrical shape as a whole. It includes a plurality of unit winding coils, the unit winding coil; It is manufactured by winding a conductor wire using a winding machine, and includes a vertical portion that is parallel to each other with a predetermined width, and a horizontal portion that is integral with the upper and lower ends of the vertical portion and is parallel to each other, and the unit winding coils adjacent to each other include the vertical portion and the vertical portion. The horizontal portions are superimposed and thermally fused to each other.

In addition, the conducting wire is; Consisting of a conductive core wire and an insulating coating covering the core wire, a plurality of strands are integrated to form a predetermined width, and the core wires at the ends of each conductor wire are interconnected with the covering removed.

In addition, a binding portion for winding and supporting the winding coil assembly is further provided outside the winding coil assembly.

In addition, the method of manufacturing a winding coil assembly of the present invention includes a forming step of winding a prepared conductor wire to produce a plurality of unit winding coils in the form of a square plate with an empty central portion; A bending step of bending the unit winding coil made through the forming step; A positioning step of arranging the unit winding coils bent through the bending step in a circumferential direction on the outer circumferential surface of the round bar type fixing jig, and arranging so that neighboring unit winding coils are partially overlapped; A binding step of tying the unit winding coils arranged around the fixing jig to suppress movement of the individual unit winding coils; And a thermal fusion step of applying heat to the unit winding coil in a state in which movement is suppressed through the binding step to fuse the overlapped portions.

In addition, the conducting wire is; It is composed of a conductive core wire and an insulating coating covering the core wire, and a plurality of strands are integrated to form a certain width, and after completion of the heat fusion step, the coating at the end of the conductor wire constituting each unit winding coil is removed and exposed to the outside. A core wire connection step of connecting the formed core wires is further included.

In addition, the unit winding coil; A vertical portion having a certain width and parallel to each other, and a horizontal portion integrally formed at the upper and lower ends of the vertical portion and parallel to each other, and the positioning step is a process of aligning the vertical portion and the horizontal portion of the neighboring unit winding coils to overlap. .

In addition, between the binding step and the thermal fusion step, a transfer step of removing the unit winding coil assembly whose position is constrained through the binding step from the fixing jig and then inserting it into a round bar-type heating rod having the same diameter as the fixing jig is performed. More included.

In addition, the heat fusion step; And a pressing heating process in which the outer surface of the unit winding coil assembly fitted in the heating rod is pressed and heated with a heating press, so that the insulating coating of the overlapped portion is fused.

In addition, the winding coil assembly of the present invention includes a forming step of winding a prepared conductor wire to produce a plurality of unit winding coils in the form of a square plate with an empty central portion; A bending step of bending the unit winding coil made through the forming step; A positioning step of arranging the unit winding coils bent through the bending step in a circumferential direction on the outer circumferential surface of the round bar type fixing jig, and arranging so that neighboring unit winding coils are partially overlapped; A binding step of tying the unit winding coils arranged around the fixing jig to suppress movement of the individual unit winding coils; It may be manufactured through a heat fusion step of fusing the overlapped portions by applying heat to the unit winding coil in a state in which movement is suppressed through the binding step.

In the winding coil assembly for a brushless motor of the present invention made as described above, since the unit winding coil connected in the circumferential direction takes the form of a square plate, the length in the vertical direction perpendicular to the circumferential direction is short, and the size of the motor can be further reduced. There are few parts, so the assembly is good, and the density of the coil is high, which improves the performance of the motor.

In addition, since the unit winding coil is bonded by a heat-sealing method, there is no fear of being deformed or separated by vibration or shock coming from the outside, so the durability and reliability of the quality are good.

1 is a block diagram showing a method of manufacturing a winding coil assembly according to an embodiment of the present invention.
2A to 2H are views schematically illustrating a method of manufacturing a winding coil assembly according to an embodiment of the present invention.
3 is a diagram showing a separate unit winding coil immediately after bending.

Hereinafter, one embodiment according to the present invention will be described in more detail with reference to the accompanying drawings.

1 is a block diagram showing a method of manufacturing a winding coil assembly according to an embodiment of the present invention, and FIGS. 2A to 2H are diagrams for schematically illustrating a method of manufacturing a winding coil assembly according to an embodiment of the present invention. . In addition, FIG. 3 is a diagram separately showing the unit winding coil immediately after bending.

The manufacturing method is a series of processes for making the winding coil assembly 40 shown in FIG. 2H. The winding coil assembly 40 is configured by connecting three unit winding coils 30 in the circumferential direction, and has a particularly short height H. The reason for the short height is that there are no protruding portions at the upper and lower ends of the unit winding coil 30. Since the height H is thus short, the length of the brushless motor itself can be shortened, and the brushless motor can be mounted even in a narrower space.

As shown, the method of manufacturing a winding coil assembly according to the present embodiment includes a forming step 101, a bending step 103, a positioning step 105, a binding step 107, a transfer step 108, and thermal fusion. Step 109, and a core wire connection step 111.

The forming step 101 is a process of manufacturing the unit winding coil 30 by winding the conducting wire 31 using the winding machine 11. The unit winding coil 30 made through the forming step 101 takes the form of a square plate having a predetermined thickness in which the central portion is empty, as shown in FIG. 2B. The central portion is a portion in which the winding machine 11 is fitted, and is a rectangular through-hole 30c left by the winding machine 11 being removed.

Both side portions of the unit winding coil 30 are vertical portions 30b, and upper and lower ends thereof are horizontal portions 30a. The vertical part 30b is a part located on the left and right sides of the through hole 30c, and the horizontal part 30a is a part located in the upper and lower parts of the through hole 30c. The horizontal portion 30a and the vertical portion 30b are orthogonal and are of course integrally formed. In addition, the two vertical portions 30b and the two horizontal portions 30a are parallel to each other and form a parallelogram shape structure. The horizontal portion 30a and the vertical portion 30b have a predetermined width, and the aspect ratio may vary as necessary.

The conductive wire 31 has three strands joined together and has a certain width. Each conducting wire 31 is constituted by a conductive core wire 31a and an insulating coating 31b covering the core wire. In addition, as described later, the core wires 31a are combined into one through a core wire connection step 111 to be described later. That is, the covering 31b at both ends of the conductive wire 31 is removed and the exposed core wire 31a is integrated. Through this core wire connection step 111, the three wires perform the same function as the one wire.

The subsequent bending step 103 is a process of bending the horizontal portion 30a of the manufactured unit winding coil 30. For example, as shown in FIG. 2C, the unit winding coil 30 is inserted into the bending device 13 and a force is applied to bend it to have a certain curvature.

The bending apparatus shown in FIG. 2C includes an upper mold 12a and a lower mold 12d. The lower part of the upper mold 12a has a protrusion 12b, and a groove 12e is formed in the upper part of the lower mold, and the unit winding coil 30 is positioned between the protrusion 12b and the groove 12e. When the protrusion 12b is lowered in the state, the unit winding coil 30 is pressed and bent in the groove 12e, resulting in the shape of FIG. 2D.

Referring to FIG. 2D, it can be seen that the horizontal portion 30a of the unit winding coil 30 is bent. At this time, the vertical portions 30b on both sides are not bent and maintain a flat state.

The positioning step 105 is a process of arranging the unit winding coil (30 in FIG. 2D) in a bent state on the outer circumferential surface of the round bar type fixing jig 15 prepared in a circumferential direction. The fixing jig 15 is an equipment having a predetermined diameter and a shape extending in the longitudinal direction.

In particular, when the unit winding coils 30 are arranged, the vertical portions 30b of the unit winding coils adjacent to each other are not overlapped. That is to say, the inner surface of the vertical portion 30b of one unit winding coil overlaps the outer surface of the horizontal portion 30a, not the vertical portion 30b of the other unit winding coil. At this time, the narrower the interval between the vertical portions 30b is better.

The subsequent binding step 107 is a process of tying a plurality of unit winding coils 30 arranged around the fixing jig 15 to prevent the unit winding coil from moving. (See Fig. 2E) In other words, the unit winding coil 30 is temporarily fixed by winding the circumference of the coil 30 with a tape 21. Positions between the unit winding coils 30 are maintained through the binding step 107. The tape 21 is one of the binding portions for supporting the unit winding coil 30, and other supporting means in place of the tape may be used. For example, rubber bands can also be used.

The transfer step 108 is a process of moving the unit winding coil assembly temporarily fixed by the tape 21 in the direction of the arrow p in FIG. 2F to the heating rod 17. The heating rod 17 takes the shape of a round rod having the same diameter as the fixing jig 15 and has a built-in heater 17a therein. In some cases, a simple round bar other than the heating bar 17 may be used.

When the unit winding coil assembly is moved in the direction of the arrow p while the end of the heating rod 17 is aligned with the fixing jig 15, the unit winding coil assembly slides over to the heating rod 17.

The thermal fusion step 109 includes a pressing heating step 109a as a process in which heat is applied to the unit winding coil assembly fitted in the heating rod 17 to fuse the overlapped portions.

In the pressing heating step 109a, the outer surface of the unit winding coil assembly supported by the heating rod 17 is pressed and heated with a heating press 19, so that the insulating coatings of the overlapping portions are fused and bonded.

The heating press 19 includes a first heating mold 19a and a second heating mold 19d each provided with a built-in heater 19b. In addition, a concave pressing groove 19c is formed on the bottom surface of the first heating mold 19a, and a pressing groove 19f corresponding thereto is provided on the upper surface of the second heating mold 19d.

With the unit winding coil assembly positioned between the first and second heating molds (19a, 19d), the first and second heating molds (19a, 19d) are brought close to the unit winding coil assembly in the pressing grooves (19c, 19f). After receiving, when the built-in heaters 17a and 19b are operated at the same time as pressurization, melting of the covering 31b starts, and in particular, the overlapped parts are integrated. When the fusion is completed, the first and second heating molds 19a and 19d are opened and cooled at room temperature.

2H is a winding coil assembly 40 manufactured through a heat bonding 109 step. In the illustrated winding coil assembly 40, the tape 21 is omitted. The tape 21 can be left or removed.

The subsequent core wire connection step 111 is a process of removing the covering 31b at the end of the conducting wire 31 and tying the exposed three core wires 31a. Removal of the coating is possible by heating the coating 31b. The coating is easily melted and removed by heat. Through the core wire connection step 111, the three wires are electrically integrated.

Meanwhile, the winding coil assembly 40 for a brushless motor according to the present embodiment has the structure of FIG. 2H.

As shown, the winding coil assembly 40 is heat-sealed after arranging three unit winding coils 30 in the circumferential direction, and takes the shape of a cylinder. A magnet (not shown) is disposed in the inner space of the winding coil assembly 40. As mentioned above, the three unit winding coils 30 are fixed in a partially overlapped state. In addition, the binding part is omitted in FIG. 2H. The binding portion is the tape 21 shown in Fig. 2F.

In the above, the present invention has been described in detail through specific embodiments, but the present invention is not limited to the above embodiments, and various modifications are possible by those of ordinary skill within the scope of the technical idea of the present invention.

11: Winding machine 13: Bending device 12a: Upper mold
12b: protrusion 12d: lower mold 12e: groove
15: fixed jig 17: heating rod 17a: built-in heater
19: heating press 19a: first heating mold 19b: built-in heater
19c: Pressurized groove 19d: Second heating mold 19f: Pressurized groove
21: tape 30: unit winding coil 30a: horizontal part
30b: vertical part 30c: through port 31: conductor
31a: core wire 31b: sheath 40: winding coil assembly

Claims (9)

delete It takes the form of a square plate with an empty central part, and includes a plurality of unit winding coils that are connected in a lateral direction in a bent state to form a cylindrical shape as a whole,
The unit winding coil is;
It is manufactured by winding a wire using a winding machine, and has a shape of a square plate, including a vertical part having a certain width and parallel to each other, and a horizontal part that is integral with the upper and lower ends of the vertical part and parallel to each other,
The unit winding coils adjacent to each other are thermally fused to each other in a state in which the vertical portion and the horizontal portion are superimposed,
The one conducting wire is made of a plurality of core wires, and each of the core wires is covered by an insulating coating,
One conductor wound on the winding machine has a shape in which a plurality of core wires and insulating sheathed strands are integrated to form a predetermined width, and the core wires at the ends of each conductor wire are for brushless motors having a structure that is interconnected with the insulating covering removed. Winding coil assembly. The method of claim 2,
A winding coil assembly for a brushless motor further provided outside the winding coil assembly with a binding portion for winding and supporting the winding coil assembly. delete Forming a plurality of unit winding coils in the form of a square plate with an empty central portion by winding the prepared conductor wire;
A bending step of bending the unit winding coil made through the forming step;
A positioning step of arranging the unit winding coils bent through the bending step in a circumferential direction on the outer circumferential surface of the round bar type fixing jig, and arranging so that neighboring unit winding coils are partially overlapped;
A binding step of tying the unit winding coils arranged around the fixing jig to suppress movement of the individual unit winding coils;
A method of manufacturing a winding coil assembly comprising a heat fusion step of fusing the overlapped parts by applying heat to the unit winding coil in a state where movement is suppressed through the binding step,
The prepared conductive wire is formed by preparing a conductive core wire, a plurality of core wires and insulating covering strands made of an insulating coating covering the core wire, and integrating the plurality of core wires and insulating covering strands with each other,
After the heat fusion step, a core wire connection step of removing the covering of the end portions of the conductor wires constituting each unit winding coil and connecting the core wires exposed to the outside is further included. The method of claim 5,
The unit winding coil is;
It includes a vertical portion that has a certain width and is parallel to each other, and a horizontal portion that is integral with the upper and lower ends of the vertical portion and is parallel to each other,
The positioning step is a process of aligning the vertical and horizontal portions of neighboring unit winding coils to overlap each other. The method of claim 6,
Between the binding step and the thermal fusion step,
A method of manufacturing a winding coil assembly further comprising a transfer step of removing the unit winding coil assembly whose position is constrained through the binding step, from the fixing jig, and then inserting it into a round bar-type heating rod having the same diameter as the fixing jig. The method of claim 7,
The heat fusion step;
A method of manufacturing a winding coil assembly comprising a pressing and heating process in which the outer surface of the unit winding coil assembly inserted in the heating rod is pressed and heated with a heating press, so that the insulation coating of the overlapped portion is fused. delete

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