JP2002034210A - Rotating machine and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotating machine, in which a stator is mounted with a coil formed by continuously winding a plurality of coil wound parts through a crossover line, having the length of minimum essentials and applying external force to the coil wound parts so as to ensure high densification, and a manufacturing method thereof. SOLUTION: This device uses a winding core 28, having a rectangular cross section and an in-line type coil frame 27 formed out of a plurality of collars 29 including a means for attaching to or detaching from the winding core. On the open part side of the collar 29, a pin 17 for hooking a wire is formed. The coil wound part 24 is wound between the collars 29, and then the wire is hooked onto the pin 17 to form a crossover line 25. By repeating this operation, a plurality of coil wound parts 24 and the crossover line 25 are formed continuously in series at the winding core 28. A self-welding wire, having an adhesive layer which is molten by heating, is used as a wire. After the completion of continuous winding operation, a plurality of wound parts are pressurized simultaneously by an integrated frame and fixed integrally by energization for heating, thereby obtaining a continuous winding coil 23 of high packing factor.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a continuous winding coil having a high space factor and realizing high efficiency and low cost of a rotating machine, and a rotating machine having a stator using the coil. It is about.

[0002]

2. Description of the Related Art A rotating machine such as a motor or a generator mainly comprises a stator and a rotor. The stator has a core formed by punching and stacking a silicon steel plate, and a plurality of coils formed by winding an electric wire, and has a structure in which a plurality of coils are incorporated in slots (grooves) arranged on a circumference of the core. In the case of an electric motor, a current is sequentially passed through these coils to generate a rotating magnetic field and rotate the rotor. On the other hand, in the case of a generator, a magnetic field is changed by rotation of a rotor, and a current flows through a coil by an induced voltage. Here, the core of the stator includes an integrated core obtained by integrally punching and stacking a silicon steel plate in a ring shape, and a split core formed by assembling a plurality of block-shaped laminated products.

[0003] The prior art relating to a method of incorporating a coil into a stator in the former case is disclosed in Japanese Patent Application Laid-Open No.
No. 115161 (prior art 1) and JP-A-63-163.
As shown in Japanese Patent No. 59751 (Prior Art 2), an inserter method is widely known. In this method, the coil is pushed in from the opening of the slot on the flat surface of the core, and the wire alignment cannot be maintained in the slot, and the space factor (the ratio of the cross-sectional area of the wire to the cross-sectional area of the slot) is reduced. Can't be higher.

In general, if the space factor is increased, a small and highly efficient rotating machine can be obtained. Therefore, in recent years, the latter split core stator has become widespread. As a prior art of a split core, as shown in Japanese Patent Application Laid-Open No. H11-220844 (prior art 3), a tooth (teeth-like projection) and a yoke (cylindrical portion) are integrated, and the core is arranged in a circumferential direction. There is a split structure. Nozzle winding is applied directly to the divided core block teeth, and after winding, they are assembled together. In this method, since winding is performed by controlling the position of the nozzle, the alignment of the electric wires is improved, and the space factor can be improved.

As another prior art of the split core, there is a structure in which the teeth and the yoke are divided into different blocks as disclosed in Japanese Patent Application Laid-Open No. H11-252842 (prior art 4). The coil is wound elsewhere, and the coil is inserted into the teeth before being assembled into the yoke. In this case, in addition to the aligned windings, it is possible to press-form the coil, and it is possible to obtain a stator of a rotating machine having a higher space factor. here,
In the former Prior Art 3 of the split core, continuous winding of the coil winding portion is possible by driving the nozzle, but no consideration is given to increasing the space factor by applying pressure molding to the coil. On the other hand, in the latter prior art 4 of the split core, although the coil can be press-formed to increase the space factor, the coil winding portion can be continuously formed without having an unnecessary length of the crossover. The winding point is not considered.

Japanese Unexamined Patent Publication No. 1-122345 (Prior Art 5) discloses a bobbin in which a star-shaped tooth portion to be fitted on the inner diameter side of a cylindrical yoke is formed and wound. In an electric motor to be mounted on a tooth portion, a flange is formed on a bobbin and a winding holding portion is formed on the flange, and a plurality of the bobbins are continuously wound adjacent to each other, and a winding is transferred between the plurality of bobbins. It is described that a portion is formed, and a transition portion is held by the winding holding portion, and a bobbin is attached to the tooth portion.

[0007]

In the rotating machine, there is a problem of increasing the space factor of the coil in terms of performance, while there is a problem of reducing the number of connection points between coil winding portions in terms of productivity. However, in the above-mentioned prior arts 1 to 5, a plurality of coil winding portions are continuously wound via a minimum length of a connecting wire, and a coil having a high density by applying an external force to the coil winding portion is used. Not considered about gaining. Furthermore, in the above-mentioned prior arts 1 to 5, even if the length of the crossover was sacrificed, the productivity itself of the coil was not sufficiently considered.

An object of the present invention is to provide a rotating machine such as an electric motor having a stator incorporating a continuous winding coil having a high space factor and a small number of connection work steps. Another object of the present invention is to provide a method of manufacturing a rotating machine for efficiently producing a rotating machine such as an electric motor having a stator incorporating a continuous winding coil having a high space factor and a small number of connection work steps. To provide.

[0009]

In order to achieve the above-mentioned object, the present invention uses a series-arranged winding frame to arrange and wire electric wires for a coil winding portion and to wire the electric wires for a crossover. The plurality of coil winding portions are continuously formed by being connected to the crossover by being hooked or entangled on a pin-shaped member, and the plurality of coil winding portions are formed in the serially arranged type winding frame. Forming a continuous winding coil by integrally forming the turn portion by pressurizing and heating to form a continuous winding coil, and thereafter removing the continuous winding coil from the serially arranged type winding frame; And incorporating the continuous winding coil removed from the series-arranged type winding frame into a stator of the rotating machine.

Further, the present invention uses a series-arranged type bobbin, and arranges and winds a self-welding wire for a coil winding portion,
For the crossover, the self-fusing wire is hooked or entangled with a pin-shaped member, so that the plurality of coil winding portions are continuously formed by the crossover, and are formed on the serially arranged winding frame. In the formed state, the plurality of coil winding portions are collectively pressed and molded and heated and energized to be integrally fixed to form a continuous winding coil. A method for manufacturing a rotating machine, comprising: a manufacturing step of removing from a bobbin; and a step of incorporating a continuous winding coil removed from a series-arranged type bobbin in the manufacturing step into a stator of the rotary machine. .

According to the present invention, in the step of assembling in the method of manufacturing a rotating machine, a stator of the rotating machine into which a continuous winding coil is incorporated is loaded with a cylindrical yoke and the continuous winding coil inside the yoke. It is characterized by being formed of a split core that is configured by combining with a tooth portion. Further, in the present invention, in the step of incorporating in the method for manufacturing a rotating machine, when a continuous winding coil is incorporated in a stator of the rotating machine, a length of a crossover between adjacent coil winding portions in the stator is required. It is characterized by the minimum. Further, the present invention provides a method of manufacturing the rotating machine, wherein a plurality of coil winding portions are collectively pressed and formed in a state where the coil winding portions are formed in a series-arranged type winding frame. It is characterized in that it is performed by using a pressure-molding piece having a corresponding projection.

The present invention also provides a method of manufacturing a rotating machine, comprising: forming a plurality of coil winding portions in a state of being formed on a series-arranged winding frame; It is characterized in that a pressing force of about 6000N or more (preferably about 10000N to about 60000N) is applied to the turning portion. Also, the present invention
In the manufacturing process in the manufacturing method of the rotating machine, the series-arranged type winding frame used has a substantially rectangular cross-sectional shape, has a length capable of arranging the plurality of coil winding portions in series, and performs winding. A core that is rotatably supported and is rotatably connected to a rotary drive source, and is formed so as to be able to be inserted into and removed from the core in a direction intersecting with the axial direction of the core, and the pin-shaped member is provided on the insertion side. A member is provided, and a plurality of collars for separating the winding core into a coil winding portion are provided.

That is, the present invention uses a series-arranged winding frame composed of a winding core having a substantially rectangular cross-section and a plurality of detachable / removable collars (for example, U-shaped) provided with means for attaching / detaching to / from the winding core. . A pin-shaped member is provided on the insertion side (opening portion side) of the collar so as to wrap or hook the wire, and after winding a coil winding portion between the collars, the wire is wrapped around the pin-shaped member and a crossover is performed. Is repeated, and a plurality of coil winding portions and crossovers are continuously formed in series on the winding core. The wire shall be a self-fusing wire with an adhesive layer that melts by heating, and after the continuous winding operation is completed, simultaneously apply pressure to the multiple winding parts with an integral frame, and energize and heat the coil winding part. And stick together. Thereafter, the brim is pulled out in the direction perpendicular to the axis of the core, and a plurality of coil winding portions connected by crossovers are drawn out in the axial direction of the core to obtain a continuous coil having a high space factor.

Further, according to the present invention, there is provided a continuous winding coil in which a plurality of coil winding portions which are aligned and wound, are formed by pressure, and are integrally fixed are connected to each other by connecting wires, and are continuously formed in the stator. The length of the crossover between the coil winding portions is minimized and incorporated in the stator. Further, the present invention is characterized in that, in the rotating machine, the stator is formed by a split core configured by connecting a cylindrical yoke portion and a tooth portion inside the continuous yoke portion into which the continuous winding coil is incorporated. I do.

[0015]

Embodiments of the present invention will be described with reference to the drawings. A rotating machine such as an electric motor or a generator such as an induction motor or a synchronous motor according to the present invention mainly includes a stator and a rotor. Figure 1
1 shows an inner rotor type rotating machine in which a rotor 2 is incorporated inside a stator 1 and rotates. FIG. 2 shows a state where the stator 1 is taken out of the housing 3. The stator 1 includes a core 4 formed by punching and stacking a silicon steel plate, and a plurality of coils 5 wound with electric wires.
A plurality of coils 5 in slots (grooves) arranged on the circumference
It has a built-in structure. In the case of an electric motor, an electric current is sequentially passed through these coils 5 to generate a rotating magnetic field and rotate the rotor 2. On the other hand, in the case of a generator, the magnetic field is changed by the rotation of the rotor 2, and a current flows through the coil 5 by the induced voltage.

Here, the stator core is formed by integrally punching and stacking a silicon steel plate in a ring shape, and an integrated core shown in FIG.
As shown in FIG. 1, there is a split core including a teeth portion 41 and a yoke portion 42, which are constructed by assembling a plurality of block-shaped laminated products. Next, the split core composed of the teeth 41 and the yoke 42 and the continuous winding coil 23 loaded on the open-slot integral core will be described with reference to FIG. The continuous winding coil 23 has a structure in which a plurality of coil winding portions 24 are connected via a connecting wire 25. Each of the coil winding portions 24 is aligned and wound and includes an insulator 26 such as a bobbin. It is constituted by being hardened integrally. FIG. 3 (a)
When the coil 5 does not fit in the slot due to the swelling of the electric wire immediately after winding on the core 6, as shown in FIG.
When the electric wire protrudes out of the slot geometrically as shown in (a), a pressure deformation is applied to the coil winding portion 24 by an external force. The continuous winding coil 23 configured as described above is
This is a coil having a high space factor, so that the size and efficiency of the rotating machine can be reduced, while the continuous winding eliminates the need for connection work between coil winding portions after the stator is assembled.

First, a winding frame structure for realizing the continuous winding coil 23 will be described. FIG. 6 shows three views (a), (b), and (c) of a bobbin (a bobbin of a serial arrangement type) according to the present invention. The series-arranged winding frame 27 according to the present invention includes a winding core 28 having a rectangular cross section made of metal (about HRC 50 to 60).
It is composed of a plurality of U-shaped collars 29. These U-shaped collars 9 are arranged at equal intervals in the direction of the rotation axis of the core 28. Then, the series-arranged type winding frame 27 supporting the winding core 28 is driven to rotate by the rotation shaft 34 so that the insulating material 26 such as a plastic bobbin or insulating paper inserted between the adjacent brims 29 can be formed. At the same time, an operation of forming a coil winding portion 24 by aligning and winding an electric wire composed of, for example, a self-fused wire, and thereafter forming the crossover wire 25 by wrapping the electric wire around the pin 17 attached to the collar 9 is repeated. As a result, the plurality of coil winding portions 24 and the connecting wires 25
Are formed continuously in series. In addition, 35 is a root portion of the serially arranged type winding frame 27, and 36 is a distal end portion of the serially arranged type winding frame 27. That is, the root portion 35 of the series-arranged winding frame 27 is rotatably supported, and the rotating shaft 34 is rotatably connected to a rotary drive source (not shown). With this configuration, when the rotating shaft 34 is rotationally driven by the rotational driving source, the electric wires are aligned and wound around the winding core 28 between the adjacent flanges 9 to form the coil winding portion 24. Become.

The U-shaped collar 29 is provided with means for attaching and detaching to and from the core 28. That is, the U-shaped collar 29 is
The core 28 is configured to be able to be inserted and removed in an intersecting direction that is substantially perpendicular to the axial direction of the core. For example, as shown in FIG. 7B, the core 28 and the U-shaped collar 2
8, a hole 30 having the same shape is formed, and the core 31 and the collar 29 can be attached and detached by inserting and removing the pin 31 attached to the plate member 40 into and from the hole 30. When the pin 31 is passed through the core 28 and the brim 29, both are fixed, and when the pin 31 is pulled out from the core 28, the pin 31 can be separated. In the structure shown in FIG.
Ball plunger 32 so that it does not fall out
The pin 33 is positioned and fixed using. U separated
The character brim 29 can be pulled out in a direction perpendicular to the axis 34 of the winding core (the direction of the arrow in FIGS. 6 and 7).

As shown in FIG. 6, a U-shaped collar 29 is provided.
A plurality of pins (pin-like members) 17 are provided on the insertion side (opening side) of the cable to tie or hook the electric wire. When one coil winding part 24 is wound, an electric wire is wrapped around or hooked on these pins 17 to form a crossover 25, and the next adjacent coil winding part 24 is formed.

Next, a method of manufacturing a continuous winding coil using the series-arranged winding frame 27 will be described. First, the core 28 and the collar 29 are separated, and an insulator 26 such as a plastic bobbin is inserted into the core 28 from the axial direction, and positioned between the collar 29 and the collar 29. Next, core 2
8. Return the collar 29 to 8 and fix them together by attaching / detaching means (or in a state where the core 28 and the collar 29 are integrated,
An insulator 26 such as insulating paper is wound between the collars 29). Then, the root portion 35 is attached to a rotation drive shaft (not shown) that is rotationally connected to a rotation drive source, with the rotation axis 34 of the winding frame 27 being aligned with the axis, and the tip portion 36 is attached to a rotation center (not shown). ). Connect the wire at the beginning of the winding to the leading end of the bobbin 27 or the terminal pin 1 of the U-shaped collar at the end.
After being wound around and fixed to the nozzle 7, the bobbin 27 is rotated while moving a nozzle (not shown) horizontally with respect to the rotation shaft 34, and a coil (not shown) is wound between the collars 37. Next, when one coil winding part 24 is formed, the nozzle is moved with three degrees of freedom, and the electric wire is tied to the tying pin 17 to form the crossover 25. This operation is repeated, and FIG.
As shown in (a), the coil winding portion 24 is formed continuously between the flange 29 and the brim 29, and the connecting wire 25 is continuously formed above the flange opening portion. The number of continuously formed coils is n-1 where n is the number of collars 29. Here, a self-bonding wire is used for the electric wire in order to solidify the wound coil winding portion 24 integrally.

After all the coil windings 24 and the crossovers 25 have been formed, both side surfaces of the coil windings 24 are pressed and formed as required, as shown in FIG. Since the coil windings 24 are arranged in series on the same axis 34, a metal (HRC 50 to 60) pressure molding piece 39 having the same number of protrusions 38 as the coil windings 24 can be formed at once. It is.

However, if the winding frame is of the circumferential arrangement type or the parallel arrangement type as shown in FIGS. 17 and 18, it is impossible to form the coil at once. The circumferentially arranged winding frame is provided with a plurality of winding cores 11 and flanges 12 in a circumferential direction of a rotatable base 10. The base 10 is provided with driving sources 15, 16 outside the bobbin so that the base 10 can rotate about the shafts 13 and 14.
Is provided. In order to continuously wind the coil, the shaft 13 is rotated to wind the coil around the core 11, and then the shaft 14 is rotated to exchange the core 11. At this time, the crossing line is the base 10
The electric wire is kinked on the kinking pin 17 attached to the wire. The winding frame of the parallel arrangement type has a plurality of cores 11 and collars 12 provided in parallel on a base 18. Base 1
Numeral 8 is fixed, and applies a winding to each winding core by moving the nozzle three-dimensionally. Similar to the cylindrical arrangement type, the coil is continuously formed while the electric wire is tied to the tie pin 17 provided on the base 18.

Further, the winding frame 27 of the series arrangement type according to the present invention
8, there is sufficient space on both sides of the winding frame 27 of the series arrangement type, and
9 has sufficient strength (applied pressure of about 6000 N or more (preferably, applied pressure of about 10000 N to about 60000 N)), and a drive source (not shown) for the pressure forming piece
Arrangement is also easy. For example, when the wire diameter is φ1.02 and the space factor (the ratio of the conductor cross-sectional area to the slot cross-sectional area) is 59.
In the case of 8%, when the pressing force for forming the slot insertion portion of the coil until it becomes substantially parallel to the stator axis was actually measured, it was necessary that at least about 6125 N per coil winding portion 24. Therefore, a pressure of about 6000 N or more (preferably, a pressure of about 10,000 N to 60,000 N) is applied to each of the coil winding portions 24 in the pressure molding piece 39.
Degree).

However, in the case of the parallel arrangement type winding frame, FIG.
When the crossover between adjacent coils is short as shown in (b), the pressure-molding piece 22 having sufficient strength is attached to the core 1.
1 cannot be inserted.

Further, the serially arranged reel 27 according to the present invention is provided.
As shown in FIGS. 15 and 16A, it is possible to cope with a case where the adjacent coil winding portions 24 are incorporated into adjacent slots of the stator. That is, as shown in FIG. 10, since the connecting wire 40 can be formed to have a length equal to the total thickness L of the flange 29 and the coil 5 in the winding frame axis direction, the connecting wire 25 between adjacent coils in the stator can be formed. However, it is possible to form a minimum necessary substantially linear shape. Therefore, it is possible to prevent the rotating machine from being unnecessarily increased in the axial direction due to the useless crossover wire length.

When the continuous winding operation is completed, power is supplied from both ends of the coil irrespective of the presence or absence of pressure molding, and the coil winding portion 24 is integrally fixed by heating with Joule heat (about 140 ° C.). Thereafter, the fixing between the core 28 and the brim 29 is released, and the U-shaped brim 29 is attached to the shaft 3 of the core 28 as shown in FIG.
4 and perpendicularly. Crossover 25 is U-shaped collar 29
No interference with the crossover 25 occurs when the collar 29 is pulled out. When the U-shaped collar 29 is removed, the tie pin 17 and the crossover 25 are automatically separated, so that the continuous winding coil 23 can be easily separated from the core 28.

Finally, the continuous coil 23 having a high space factor can be obtained by extracting the plurality of coil winding portions 24 left on the core 28 in the axial direction of the core 28. When the core 28 and the coil winding part 24 are separated from each other, since the connecting wire 25 is separated from the connecting pin 17,
The productivity can be improved without hindering the separation between the coil winding portion 24 and the winding core 28. However,
In the case of the circumferentially arranged or parallel arranged type winding frame as shown in FIG. 17B or FIG.
Are still entangled with the pins 17, and it is necessary to remove them, resulting in poor productivity. According to the above procedure, a continuous winding coil 23 having a high space factor and a plurality of coil winding portions 24 connected via a connecting wire 25 having a minimum length can be obtained.

Next, an embodiment of the arrangement of the pins 17 and the way of tying the crossover 25 will be described. FIGS. 12 (a) to 12 (e)
13 (a) to 13 (e) are views of the series-arranged type winding frame 27 around which the coil is wound as viewed from the open side of the U-shaped collar 29, and the white circles shown in the drawings. The pin 17 is a pin, and a thick line indicates a crossover line 25. The black circle at the end of the thick line indicates the beginning or end of winding of the coil (the trapezoidal portion with a horizontal line in the figure is the coil winding portion 24).

First, a case where the winding start and end positions are separated before and after the coil winding portion 24 is shown in FIG.
This will be described with reference to (a) to FIG. 12 (e) and FIG. 13 (a).
12 (a) to 12 (c) show the case where all the coil winding portions have the same winding direction. When the electric wire is twisted as shown in FIG. 12A, the completed coil winding portion has the connecting wires 25 of the same length, and the continuous winding coil 23a shown in FIG. 14A is formed. To minimize the length of the crossover with the same shape, as shown in FIG.
And the electric wire is put on the open portion of the U-shaped collar 29 to form the crossover 25. In this case, when the coil winding portion 24 is incorporated in the core, the crossover 25 between the adjacent coils can be minimized as shown in FIG. Can be

Further, as shown in FIG.
14 (b), a continuous winding coil 23b having a partially long connecting wire 25 shown in FIG.
Can be made. Next, FIGS.
13 (e) and FIG. 13 (a) show that the winding directions of the coils are alternately reversed. When the electric wire is tangled as shown in FIG. 12D, it is possible to produce a continuous winding coil 23c shown in FIG. 14C having a crossover having the same length as the completed coil. In order to minimize the length of the crossover with the same shape, the pins 17 are arranged as shown in FIG. 12 (e), and the electric wire is wrapped using the inner edge of the U-shaped collar 29. In this case, when the coil is incorporated in the core, the crossover between the coils can be made substantially linear as shown in FIG. 16A, and the motor can be reduced in size. Also,
As shown in FIG. 13 (a), if the wire is overlapped between the pins 17, a continuous winding coil 23d having a partially long crossover 25 is made as shown in FIG. 14 (d). It becomes possible.

Next, the case where the winding start and winding end positions are on one side of the coil will be described with reference to FIGS. 13 (b) to 13 (e). 13 (b) and 13 (c).
Is the case where all the coils have the same winding direction. FIG.
When the electric wire is tangled as shown in FIG. 14B, the completed coil has the connecting wires 25 of the same length, and it is possible to produce the continuous winding coil 23e shown in FIG. Also,
As shown in FIG. 13C, if the electric wire is wrapped between the pins 17 so as to overlap, a continuous winding coil 23f having a partially long crossover 25 shown in FIG. It becomes possible. Next, FIGS. 13D and 13E show that the winding directions of the coils are alternately reversed. When the electric wire is twisted as shown in FIG. 13D, the completed coil has the connecting wires 25 of the same length, and it becomes possible to produce a continuous winding coil 23g shown in FIG. 14G. FIG.
As shown in FIG. 14E, if the wires are overlapped between the pins 17, a coil having a partially long crossover 25 can be formed as shown in FIG.

As described above, FIGS. 14 (a) and 14 (c)
(E) Coil 23a, 23c, 23e, 2 shown in (g)
3g, the length of the crossover is equal, and the coils are arranged at equal intervals in the circumferential direction and assembled to the core as shown in FIG.
Also, the coil 2 shown in FIGS. 14 (b), (d), (f), and (h)
If the length of the crossover is partially changed as in 3b, 23d, 23f and 23h, the coil can be arranged at an arbitrary position in the circumferential direction. For example, as shown in FIG. 15, it is possible to make two coils adjacent to each other and correspond in the core.

That is, as shown in FIGS. 11 and 15, the continuous winding coil 23 can be incorporated in a divided core obtained by dividing the teeth 41 and the yoke 42 or an open-slot integral core. Rotating machines using these stators are compact and highly efficient. In addition, there is no need to connect the coil winding portions with solder or the like by the continuous winding, and the cost can be reduced. Further, since there is no defect associated with the connection, a rotating machine with high insulation reliability can be obtained.

[0034]

According to the present invention, by using a series-arranged bobbin, a continuous space in which a plurality of winding portions are connected via a crossover having a high space factor and a necessary minimum length. A wound coil can be obtained, and by using this coil for a stator of a rotating machine, a small-sized, high-efficiency rotating machine can be realized. In addition, connection work between coil winding parts is eliminated,
It is possible to reduce the cost of the rotating machine and improve insulation reliability. Further, according to the present invention, by using a series-arranged type winding frame, pressure forming of a plurality of coil winding portions can be performed collectively, and separation of a core and a coil winding portion can be easily performed. And a continuous winding coil can be efficiently produced in a short time.

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional perspective view showing an inner rotor type rotating machine according to the present invention.

FIG. 2 is a perspective view showing one embodiment of a stator of an inner rotor type rotating machine according to the present invention.

FIGS. 3 (a) and 3 (b) are views showing a coil shape immediately after winding an electric wire around a core and a coil shape after pressure molding.

FIGS. 4A and 4B are views showing a state in which a coil winding portion that cannot be geometrically incorporated into a status lot is press-formed.

FIG. 5 is a perspective view showing one embodiment of a continuous winding coil according to the present invention.

FIGS. 6A and 6B are views showing an embodiment of a series-arranged winding frame structure according to the present invention, wherein FIG. 6A is a plan view, FIG.
(C) is a side view.

FIGS. 7A and 7B are views showing the attachment / detachment means for the core and the U-shaped collar in the series-arranged winding frame according to the present invention, wherein FIG. 7A is a cross-sectional view taken along the line BB in FIG. Is a side sectional view.

FIG. 8 is a view showing an embodiment in which a coil winding portion formed on a series-arranged type winding frame according to the present invention is collectively pressed and formed.

FIG. 9 is a view showing a state in which the winding core and the U-shaped collar of the serially arranged winding frame according to the present invention are separated.

FIG. 10 is a view showing an example of formation of a crossover in a serially arranged winding frame according to the present invention.

FIG. 11 is a view showing an embodiment in which the continuous winding coil according to the present invention is incorporated in a divided core having teeth and a yoke as separate bodies.

FIG. 12 is a diagram for explaining a method of forming continuous winding coils of various forms according to the present invention using a series-arranged winding frame;

FIG. 13 is a view for explaining a method of forming continuous winding coils of various forms according to the present invention using a series-arranged winding frame.

14 is a perspective view showing various types of continuous winding coils according to the present invention manufactured by the methods shown in FIGS. 12 and 13. FIG.

FIG. 15 is a view showing one embodiment in which each of the coil winding portions of the continuous winding coil according to the present invention, in which the number of crossover wires is minimized, is incorporated into each of adjacent teeth of the split core.

FIG. 16 illustrates an embodiment for reducing the size of a motor by making a crossover wire in a continuous winding coil according to the present invention to a necessary minimum and making a substantially linear shape to incorporate adjacent coil winding portions into adjacent teeth. FIG.

17A and 17B are views showing a comparative example in which a circumferentially arranged winding frame is used, wherein FIG. 17A is a perspective view showing a state of a winding, and FIG. FIG.

FIGS. 18A and 18B are views showing a comparative example in which a parallel arrangement type winding frame is used, wherein FIG. 18A is a perspective view showing a state of a winding, and FIG. It is.

19A is a diagram showing an example of the formation of a crossover in the circumferentially arranged winding frame described with reference to FIG. 17, and FIG. 19B is a diagram showing FIG.
It is a figure which shows the example of formation of the crossover in the parallel arrangement | positioning type winding frame demonstrated in FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Stator, 2 ... Rotor, 3 ... Housing, 4 ... Core, 5 ... Coil, 6, 11 ... Core, 7 ... Coil slot insertion part, 8 ... Slot, 17 ... Kink pin (pin-shaped member), 23, 23a to 23h ... continuous winding coil, 24 ...
Coil winding part, 25 crossover, 26 insulator, 27 series-arranged winding frame, 28 core of series-arranging type winding frame, 29
... U-shaped collar (brim), 30 ... hole, 31 ... fixing pin, 3
2 ... Ball plunger, 33 ... Separation prevention pin, 34 ... Rotating shaft of series-arranged type bobbin, 35 ... Root part of series-arranged type bobbin, 36 ... Tip end of serially-arranged type bobbin, 37 ... Collar Between the flange and the collar, 38: a projection for pressing, 39: a pressure piece for a winding frame of a serial arrangement type, 41: teeth of a divided core, 42 ...
Split core yoke.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H02K 15/04 H02K 15/04 C 15/12 15/12 C (72) Inventor Yuji Enomoto Yokohama, Kanagawa Prefecture 292, Yoshida-cho, Totsuka-ku, Hitachi, Ltd.Production Technology Laboratory (72) Inventor Noriaki Yamamoto 292, Yoshida-cho, Totsuka-ku, Yokohama, Kanagawa, Japan Hitachi, Ltd. 7-1-1 Higashi Narashino, Narashino-shi F-term within Hitachi, Ltd. Industrial Equipment Group (Reference) 5H002 AA00 AA07 AB06 AC06 5H603 AA09 BB01 BB02 BB08 BB09 BB10 BB12 CA01 CA05 CB01 CB16 CB22 CC11 CC18 CD21 CD32 FA04 FA18 BB01 BB09 BB10 BB14 BB17 CC01 CC05 CC16 DB01 DB15 DB19 QB17 5H615 AA01 BB06 BB07 BB14 PP01 PP06 PP12 QQ02 QQ19 RR04 SS03 SS11 S S19 SS24 TT28

Claims (9)

[Claims] An electric wire is arranged and wound for a coil winding portion by using a series-arranged type winding frame, and the electric wire is hooked or entangled with a pin-like member for a crossover, thereby forming a plurality of the electric wires. The coil windings are continuously formed by connecting the crossovers, and the plurality of coil windings are collectively pressed and heated in a state where the coil windings are formed in the series-arranged type winding frame, thereby being integrally formed. Forming a continuous winding coil, and then removing the continuous winding coil from the series-arranged winding form; and a continuous winding coil removed from the series-arrangement-type winding form in the manufacturing step. And a step of assembling into a stator of the rotating machine. 2. A self-fusing wire is aligned and wound for a coil winding portion using a serially arranged winding frame, and for a crossover wire, the self-fusing wire is hooked or entangled with a pin-shaped member. Thereby, the plurality of coil winding portions are continuously formed by connecting the crossover wires, and the plurality of coil winding portions are collectively pressed and formed in a state where the plurality of coil winding portions are formed in the serially arranged type winding frame. A continuous winding coil is formed by being fixed by applying electric current to form a continuous winding coil, and then the continuous winding coil is removed from the series-arranged type bobbin. Incorporating the removed continuous winding coil into a stator of the rotating machine. 3. The step of assembling, wherein the stator of the rotating machine into which the continuous winding coil is incorporated is formed by connecting a cylindrical yoke portion and an inner tooth portion into which the continuous winding coil is loaded. The method for manufacturing a rotating machine according to claim 1, wherein the rotating machine is formed of a split core. 4. A method according to claim 1, wherein the step of assembling the continuous winding coil into a stator of a rotating machine is such that a length of a crossover between adjacent coil winding portions in the stator becomes a necessary minimum. The method for manufacturing a rotating machine according to claim 1, 2 or 3. 5. In the manufacturing process, when a plurality of coil winding portions are collectively pressed and formed in a state of being formed on a series-arranged type winding frame, a projection having a projection corresponding to each of the coil winding portions is provided. The method for manufacturing a rotating machine according to any one of claims 1 to 4, wherein the method is performed by using a pressure forming piece. 6. In the manufacturing process, when a plurality of coil winding portions are collectively pressed and formed in a state of being formed on a series-arranged type winding frame, 6000 N is applied to each of the coil winding portions.
2. A pressing force of a degree or more is applied.
5. The method for manufacturing a rotating machine according to any one of claims 4 to 4. 7. In the manufacturing process, the series-arranged type winding frame used has a substantially rectangular cross-sectional shape, has a length capable of arranging the plurality of coil winding portions in series, and can be wound. A core rotatably supported and rotatably connected to a rotary drive source, and a pin-shaped member formed on the insertion side such that the core can be inserted into and removed from the core in a direction intersecting the axis of the core. The method for manufacturing a rotating machine according to any one of claims 1 to 6, further comprising: a plurality of flanges for separating the winding core into coil windings. 8. A continuous winding coil formed by continuously winding a plurality of coil winding portions which are aligned, formed by pressure, and fixed integrally with each other by a connecting wire, and which are continuously wound in an adjacent coil winding in a stator. A rotating machine characterized in that the length of the connecting wire between the parts is minimized and incorporated into the stator. 9. The stator according to claim 8, wherein the stator is formed of a split core formed by connecting a cylindrical yoke portion and a tooth portion inside the continuous yoke coil into which the continuous winding coil is incorporated. Rotating machine.