JPH0471352A - Manufacture of cylindrical coil - Google Patents

Abstract

PURPOSE:To improve the accuracy of a shape and a space factor by preparing a spiral external coil element piece group, which is inscribed in a virtual external cylindrical body, is extended in parallel with a central axis while being turned around the central axis and has specified width. CONSTITUTION:Spiral external coil element pieces 11, 12, 13... inscribed in a virtual external cylindrical body 10' are arrayed while interposing thin electric insulating layers combining adhesive layers, thus preparing an external cylindrical body 10 having the same shape as the virtual cylindrical body 10'. Spiral internal coil element pieces 21, 22 23... inscribed in a virtual internal cylindrical body 20' having the outside diameter smaller than the inside diameter of the cylindrical body 10' are arrayed while interposing thin electric insulating layers combining adhesive layers, thus preparing an internal cylindrical body 20 having the same shape as the virtual cylindrical body 20'. The internal cylindrical body 20 is housed in the external cylindrical body 10 while interposing electric insulating layers, and the opposed coil element piece in the coil element pieces on the inside and the outside are welded mutually at the upper end sections and lower end sections of the coil element pieces, and coupled electrically and mechanically. Accordingly, a cylindrical coil having high accuracy and a high space factor can be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method of manufacturing a cylindrical coil used in a rotary electro-mechanical energy conversion device such as a motor or a generator.

(Prior art) A general-purpose brushless DC motor detects the rotational position of a rotor magnet inside a cylindrical coil using a magnetic sensor, etc.7, and sequentially applies electricity to multiple phase coils inside the cylindrical coil in synchronization with this rotational position. The structure is such that a rotating magnetic field is generated by flowing the magnet, and continuous rotational torque is generated in the rotor magnet. For details on the operating principle and structure of this brushless DC motor, please refer to the
7-14110 etc.

Methods for manufacturing cylindrical coils used in such brushless DC motors include the above-mentioned patent publications and Japanese Patent Application Laid-Open No. 1988-62.
A method of processing a winding wire as disclosed in Japanese Patent Publication No. 244251, etc., and a method of processing a helical sheet as disclosed in Japanese Patent Publication No. 60-35900 are known.

Other manufacturing methods for cylindrical coils include Japanese Patent Application Laid-open No. 61-1
As disclosed in Japanese Patent No. 0934, there is a method in which a cylindrical body in which linear coil pieces are arranged is twisted around its axis to cause each coil piece to be spirally deformed.

That is, as shown in the perspective view of FIG. 7, by twisting the outer cylindrical body 50, in which linear coil pieces 51, 52, 53, etc. are arranged with an electrically insulating layer interposed therebetween, around its axis ( A), individual coil pieces 51.52.53
... causes a spiral deformation (R). In addition, as shown in FIG. 8, linear coil pieces 61, 62, 63,
(A) By twisting the inner cylindrical body 60, which has a smaller diameter than the inner diameter of the cylindrical body arranged with an electrically insulating layer in the opposite direction around its axis, the individual coil pieces 61, .
Create a spiral deformation in 62.63... (R). Next, as shown in FIG. 9, the inner cylindrical body 60 is inserted into the outer cylindrical body 50 with an electrically insulating layer interposed therebetween, and the lower ends of the opposing coil pieces are electrically and mechanically connected by welding or the like. Connect to.

If the center lines of the inner and outer coil pieces are laid out on a plane, the result will be as shown in FIG. 4. In this figure, only a part of the coil segment group that constitutes one layer of coils is shown in order to avoid complexity. When the coil is energized, currents flow in opposite directions to the adjacent inner and outer coil pieces, so N poles and S poles appear alternately between the two pieces.

A rotating magnetic field that rotates in the circumferential direction can be generated by sequentially passing a current through the coils of each layer formed so as to be shifted in the circumferential direction.

(Problems to be Solved by the Invention) Among the conventional methods for manufacturing cylindrical coils described above, those that process windings and helical sheets produce unnecessary bends, which leads to poor shape accuracy and space factor. The problem is that it is difficult to do.

In addition, even with the manufacturing method in which linear coil pieces are arranged in a cylindrical shape and twisted, it is not possible to give a uniform twist due to variations in the material of the coil pieces, resulting in improved shape accuracy and space factor. The problem is that it is difficult.

(Means for Solving the Problems) A method for manufacturing a cylindrical coil according to the present invention provides a method for manufacturing a cylindrical coil of a predetermined width that is inscribed in a virtual outer cylinder and extends parallel to the central axis while rotating around the central axis. a step of creating a group of spiral outer coil pieces; and creating a spiral inner coil piece group that extends parallel to the central axis with a slightly smaller width than the outer coil pieces while rotating in the opposite direction to the outer coil pieces around the central axis. , a step of creating an outer cylindrical body having the same shape as the virtual outer cylindrical body by arranging a group of outer coil pieces with an electrically insulating layer interposed therebetween, and a step of arranging a group of inner coil pieces with an electrically insulating layer interposed therebetween. A process of creating an inner cylinder having the same shape as the above-mentioned virtual inner cylinder by arranging the inner cylinder while arranging the inner and outer coil pieces. A step of overlapping the upper and lower end portions in the diurnal direction, and a step of electrically connecting the inner and outer coil segment groups that are opposed or circumferentially adjacent to each other at one end and the lower end of each. including
The structure is such that it is possible to manufacture a cylindrical coil with high precision and a high space factor.

Hereinafter, the operation of the present invention will be explained in detail together with examples.

(Example) First, as shown in Fig. 1, a hypothetical outer cylindrical body 10゜ of a predetermined length and wall thickness is assumed. A predetermined number of spiral outer coil pieces 11 of a predetermined width extending from a conductor such as a copper alloy or an aluminum alloy are made.

Concurrently, as shown in FIG. 2, a hypothetical inner cylindrical body 20'' is assumed, which has approximately the same length as the hypothetical outer cylindrical body 10'' and an outer diameter smaller than its inner diameter. A spiral outer coil piece 21 is inscribed in this, extends parallel to the central axis while rotating around the central axis, and has a width slightly smaller than the outer coil piece 11. A predetermined number of pieces are made from the same material.The maximum turning angle between the upper and lower ends of this inner coil piece is the same as that of the outer coil piece, but the turning direction is opposite to that of the outer coil piece.

Next, as shown in FIG. 3, outer coil pieces 11.1.
By arranging 2.13... while interposing a thin electrically insulating layer that also serves as an adhesive layer such as epoxy resin, an outer cylindrical body 1 having the same shape as the virtual outer cylindrical body 10 described above is created.
Create 0.

Similarly, as shown in FIG.
An outer cylindrical body 20 having the same shape as the virtual inner cylindrical body 20'' described above is created by arranging the L 22, 23, .

Subsequently, as shown in FIG. 5, the inner cylindrical body 20 is accommodated in the outer cylindrical body 10 with an electrically insulating layer interposed therebetween, and the lower end portions of the inner and outer coil pieces are overlapped in the circumferential direction. match. As the electrical insulating layer in this case, an epoxy resin adhesive or the like is selected so that it also serves as an adhesive.

Next, as shown in FIG. 6, by welding the opposing inner and outer coil pieces at their respective upper and lower ends as shown by 3132, 33... Connect electrically and mechanically. Also, one of the inner and outer coil pieces in the circumferential direction.
The wires 41 are adjacent to each other with a pitch difference.
．． 42, 43, etc., and connect electrically by soldering or the like.

The cylindrical coil according to the manufacturing method of the present invention can be applied not only to brushless DC motors but also to electric-mechanical energy conversion devices including DC generators, induction machines, synchronous machines, etc., and as electromagnets. .

(Effects of the Invention) Since the method for manufacturing a cylindrical coil according to the present invention is configured as described above, it is possible to manufacture a tube coil with high precision and a high space factor.

In addition, since the manufacturing method of the present invention does not require winding or twisting linear coil pieces, a wide range of conductors, including conductors made of brittle materials such as superconductors, can be used as coil pieces. It also has the advantage that it can be used as

[Brief explanation of the drawing]

1 to 6 are perspective views for explaining each step of a method for manufacturing a cylindrical coil according to an embodiment of the present invention, and FIGS. 7 to 9 are perspective views for explaining a conventional method for manufacturing a cylindrical coil. The perspective view and FIG. 10 are conceptual diagrams for explaining an example of the operation of a general cylindrical coil. 10゛...Virtual outer cylindrical body, 10...Outer cylindrical body, 11.12.13...Spiral coil piece formed on the outer cylindrical body, 20...Virtual Outer cylindrical body, 20... Inner cylindrical body, 21.22.23...
Spiral coil piece formed in the inner cylindrical body, 31,3
2.33... Welding part that electrically and mechanically connects the opposing ends of the inner and outer coil pieces, 41.42
゜43...Wire for electrically connecting the upper ends of inner and outer coil pieces adjacent to each other in the circumferential direction. Patent applicant Honda Motor Co., Ltd.

Claims (1)

[Claims] A step of creating a group of spiral outer coil pieces of a predetermined width that are inscribed in a virtual outer cylindrical body and extend parallel to the center axis while rotating around the center axis; Inscribed in a virtual inner cylindrical body having approximately the same length as the virtual outer cylindrical body and an outer diameter smaller than the inner diameter of this outer cylindrical body, and opposite to the outer coil piece around the central axis. creating a spiral inner coil piece group that extends parallel to the central axis with a width slightly smaller than the outer coil piece while rotating in the same direction; and coating the outer coil piece group with an electrically insulating layer. a step of creating an outer cylindrical body having the same shape as the virtual outer cylindrical body by arranging the inner coil pieces with an electric insulating layer interposed therebetween; creating an inner cylindrical body having the same shape as the cylindrical body; accommodating the inner cylindrical body with an electrically insulating layer interposed in the outer cylindrical body, and aligning both upper and lower ends of the inner and outer coil pieces in the circumferential direction; A cylinder characterized by comprising the steps of: overlapping the inner and outer coil pieces; and electrically connecting the inner and outer coil pieces that are opposed or circumferentially adjacent to each other at their respective upper and lower ends. How to manufacture coils.