JPH0241270B2 - - Google Patents

Description

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

In a coil in which an inner layer coil portion and an outer layer coil portion are formed separately, the two are fitted together, and the ends of the coil wires appearing at both ends are fitted to each other using a laser or the like to form a closed loop. The winding method includes a honeycomb coil 1 as shown in Figs. 1 and 2, a tortoiseshell coil 2 as shown in Figs. 3 and 4, a wave coil 3 as shown in Figs. 5 and 6, etc. is considered.

However, among these, the hexagonal type and the corrugated type have a disadvantage that they have a higher flux linkage than the honeycomb type and are more efficient but have poor productivity.

Therefore, an object of the first invention is to provide a method for manufacturing a coil for a coreless motor, which can manufacture coils of hexagonal and wave-shaped winding methods with high production efficiency.

The first embodiment of the first invention is shown in FIGS.
This will be explained with reference to Figure 3. That is, this is to form a hexagonal coil, and first, an outer layer coil portion and an inner layer coil portion are formed by the following method. 7th
As shown in the figure, a predetermined number of guide protrusions 4 are formed at equal intervals in the circumferential direction, and a plurality of sets of core metals 5 are arranged in the axial direction (FIG. 7). As shown in FIG. 8, a large number of coil wires 6 are aligned parallel to the axis and positioned between the protrusions 4 on this core metal 5, thereby forming cylindrical bodies 7 arranged at regular intervals in the circumferential direction. . As shown in FIG. 9, fixed portions 8 are formed by fixing coil wires 6 of a predetermined width at regular intervals in the axial direction of this cylindrical body 7 with an adhesive. As shown in FIG. 10, the fixed parts 8b and 8c on both sides of one fixed part 8a are fixed, and the fixed part 8a in the middle is rotated in one direction as shown by the arrow. In this way, the unfixed parts 9 and 10 between the fixed parts 8a and 8b and between the fixed parts 8a and 8c are twisted spirally, and the fixed parts 8b and 8c are drawn toward the fixed part 8a, and the gap between the coil wires is reduced. They become narrower and come into contact with each other. Then, the position P ₁ indicated by the dashed line in the center of the unfixed parts 9 and 10,
Cut at P ₂ . Thus, Figures 11 and 12
As shown in the figure, an outer layer coil portion 11 or an inner layer coil portion 12 is formed. These outer layer coil parts 11
The inner coil portion 12 is formed such that the outer diameter of the inner coil portion 12 is equal to the inner diameter of the outer coil portion 11, and the directions of inclination of the spiral portions 9 and 10 with respect to the fixed portion 9 are opposite to each other.

These outer layer coil portions 11 and inner layer coil portions 12 are fitted together, and the coil wire ends 1 of the inner and outer layer coil portions 11 and 12 are formed at both ends as shown in FIG.
3 and 14 are joined together using a laser or the like. In this way, a tortoiseshell-shaped coil that becomes a closed loop is formed. A shaft and a commutator are attached to this coil, and the segments and coil terminals are connected to form a motor rotor.

With this configuration, tortoiseshell-shaped coils with a large amount of interlinkage magnetic flux can be continuously manufactured, and productivity can be improved.

A second embodiment of the first invention will be explained with reference to FIGS. 14 to 17. That is, this forms a wave-shaped coil, in which a cylindrical body 16 is formed by coil wires 15, and fixed parts 17 are attached at regular intervals.
The formation of unfixed parts 18 and 18 is similar to the first embodiment, and as shown in FIG. 15, one fixed part 1
Adjacent fixed parts 17 so that the spiral winding directions of unfixed parts 18a and 18b at both ends of 7a are in the same direction.
Rotate b. In contrast to the outer layer coil portion 19 formed in this way, the inner layer coil portion 20 is the 17th coil portion.
As shown in the figure, by forming the unfixed parts 21a and 21b in opposite winding directions, fitting the coil parts 19 and 20 together, and joining the ends of the coil wires exposed at both ends, a closed loop is formed. A wave-shaped coil is obtained. Therefore, it has the same effect as the first embodiment.

As described above, in the method for manufacturing a coil for a coreless motor according to the first invention, coil wires are arranged circumferentially at predetermined intervals to form a cylindrical body, and the coil wires are fixed at regular intervals in the axial direction. Since the outer layer coil portion and the inner layer coil portion are formed by twisting the fixed portions in a certain direction and cutting them at the spiral portion, a corrugated or hexagonal coil portion with good productivity can be obtained. There is an effect.

By the way, although the honeycomb type coil has better productivity than the conventional hexagonal type coil, it has the following drawbacks in joining the coil wire ends 25 and 26 as shown in FIGS. 18 and 19. In other words, (1) Because the wires of the inner layer coil portion and the outer layer coil portion are close to each other during end face bonding, there is no possibility that the heat generated during bonding will destroy the insulation coating of the coil wires and cause shorts. It was a lot.

(2) When the end faces are joined, if the positions of the corresponding coil wires of the inner and outer layer coil parts are shifted in the circumferential direction,
Since joining becomes difficult, high precision was required in positioning the inner and outer layers.

Moreover, in order to eliminate these drawbacks in the honeycomb type, a pin 28 is embedded in the core metal 27 as shown in FIG. and the second
As shown in FIG. 2, a method has been developed in which the end surfaces 31 and 32 are joined together so that they are parallel to the axial direction. By doing this, a gap is formed between the adjacent parts 30' of the coil wire, so the thermal effect during bonding is reduced, and a slight positional shift between the wires between the inner and outer layers causes the wires to move. I was able to fix it by doing this. However, this method had the disadvantage of poor productivity because continuous production was difficult.

Therefore, a second object of the invention is to provide a method for manufacturing a coil for a coreless motor in which the ends of the coil wires can be reliably and easily joined, and the productivity is high.

An embodiment of the second invention is shown in FIGS. 23 to 26.
This will be explained using figures. That is, the core metals 33, 33'
A large number of coil wires 34 are spirally wound to form an inner layer cylindrical body 35 as shown in FIG. 23 and an outer layer cylindrical body 36 as shown in FIG.
Adhesive parts 37, 37 of a predetermined width are formed with adhesive at regular intervals in the axial direction of 5, 36, and then adjoining adhesive parts 37, 37' are formed as shown by the arrows in FIG.
rotate in the opposite direction to remove the unfixed parts 38, 3 between them.
Unscrew it so that the coil wire 34 of 8' becomes parallel to the axial direction as shown in FIG. As a result, a gap H is formed between the coil wires in this portion. A circumferential groove is formed (not shown) in the unfixed portions 38, 38' as shown by the dashed lines, and the coil wire 34 is stripped and separated by cutting at the circumferential groove. The thus formed outer layer coil portion and inner layer coil portion are fitted into each other, and both ends of the coil strands which are parallel to the axis are joined together to form a coil as in FIG. 22.

With this configuration, the end portion of the coil has a small thermal effect on the adjacent wire due to the gap H when end faces are joined, so the probability of shortening is reduced, and stable joining can be performed. Furthermore, since the joint line can be moved freely, there is no need for highly accurate positioning of the inner and outer layers. Moreover, the productivity is better than the conventional method shown in FIG. Further, if the circumferential groove is formed before cutting, processing and joining will be made easier.

Note that a large number of coil wires 34 are connected to core metals 33, 3.
3', the guide protrusion 4 shown in Fig. 7 is formed in a spiral shape on the core bars 33, 33', and the coil wire 34 is guided by the guide protrusion 4 and wound. It's okay.

As described above, in the method for manufacturing a coil for a coreless motor according to the second invention, a large number of coil wires are spirally wound to form a cylindrical body, fixed parts are formed at regular intervals, and the fixed parts are rotated. The coil wire in the unfixed part is screwed back so that it is parallel to the axial direction, and the unfixed part is cut to form an inner layer coil part and an outer layer coil part, so compared to the first invention. Since the gap in the circumferential direction between the ends of the coil wire becomes large, there is no risk of short circuit between the ends.
In addition, when joining the ends of the coil wire between the inner layer coil part and the outer layer coil part, since the gap is large in the circumferential direction at both ends, there is a margin for mutual positioning, so the ends of the coil wire are joined. This has the effect of making it easier and improving productivity.

[Brief explanation of drawings]

Figure 1 is a schematic perspective view of a honeycomb coil;
Figure 3 is a schematic perspective view of the hexagonal coil, Figure 4 is a schematic perspective view of the hexagonal coil, Figure 5 is a schematic perspective view of the wave-shaped coil, Figure 6 is its expanded view, and Figure 7 is a schematic perspective view of the hexagonal coil. A perspective view of the core metal used in the first embodiment of the first invention, FIG. 8 is a perspective view of the state in which the coil wire is positioned on the core metal to form a cylindrical body, and FIG. 9 is a perspective view of the fixed part. 10 is a side view of the unfixed portion twisted into a spiral shape, FIG. 11 is a perspective view of the outer layer coil portion, FIG. 12 is a perspective view of the inner layer coil portion, and FIG. 13 is a side view of the formed state. The figure is a partially enlarged perspective view of the end of the coil part, Figure 14 is a side view of the cylindrical body of the second embodiment with the fixed part formed, and Figure 15 is the unfixed part twisted into a spiral shape. Fig. 16 is a perspective view of the outer coil part, Fig. 17 is a perspective view of the inner coil part, Fig. 18 is a perspective view of a conventional honeycomb coil, and Fig. 19 is a partially enlarged view of its end. Perspective view, 2nd
Figure 0 is a perspective view showing how the coil part is formed by another conventional manufacturing method, Figure 21 is an enlarged perspective view of the main part thereof, Figure 22 is a partially enlarged perspective view of the end of the coil, and Figure 23 is a coil part for the inner layer. FIG. 24 is a perspective view of the cylindrical body for the outer layer, and FIGS. 25 and 26 are perspective views showing the process of forming unfixed portions parallel to the axis. 6, 15, 34... Coil wire, 7, 16...
Cylindrical body, 8, 17, 37, 37'... fixed part, 9,
10, 18, 38, 38'...unfixed part, 11,
19... Outer layer coil part, 12, 20... Inner layer coil part, 13, 14... End surface.

Claims (1)

[Scope of Claims] 1. For a coreless motor in which a closed loop is formed by fitting together an outer layer coil portion and an inner layer coil portion that are formed separately, and joining the ends of the coil wires exposed at both ends of the coil portions. A method for manufacturing a coil, in which a large number of coil wires are arranged parallel to each other in the axial direction and arranged at regular intervals in the circumferential direction to form a cylindrical body, and the coil wires are arranged at regular intervals in the axial direction of this cylinder with a predetermined width. Form a wire fixed part, rotate these fixed parts in opposite directions to each other to form a spiral part in the fixed part, and by cutting the cylindrical body at this spiral part, the fixed part is positioned in the center. A method for manufacturing a coil for a coreless motor, comprising forming an outer layer coil portion or an inner layer coil portion. 2. A method for manufacturing a coil for a coreless motor, in which a closed loop is formed by fitting together an outer layer coil portion and an inner layer coil portion that are formed separately, and joining the ends of the coil wires exposed at both ends of the coil portions. Then, a large number of coil wires are spirally wound in the axial direction to form a cylindrical body, and coil wire fixing parts are formed with a predetermined width at regular intervals in the axial direction of this cylinder, and these fixed parts are For a coreless motor, the coreless motor is characterized in that adjacent parts are rotated in opposite directions to form a parallel part between fixed parts, and the cylindrical body is cut at this parallel part to form an outer layer coil part or an inner layer coil part. How to manufacture coils.