JP2006238687A - Coil, coil unit, stator and rotor, tool for manufacturing coil and coil unit, and method of manufacturing coil and coil unit - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil unit and an armature which have an improved space factor and are easily manufactured irrespective of the shape of a wire rod. <P>SOLUTION: The coil unit employs a continuous multi-stage system which chains a plurality of coils continuously in such a configuration that one wire rod 2 is wound with the shape having at least two sets of opposing two-side pairs. For the opposing two sides, one is a first side 6a, and the other is a third side 6c. For the rest of the opposing two sides, one is a second side 6b, and the other is a fourth side 6d. The directions 6i and 6k in which the coils on the first side 6a and the third side 6c of a pair are respectively stacked are essentially the same, while the directions 6j and 6l in which the coils on the second side 6b and the fourth side 6d of another pair are respectively stacked are reverse to the directions 6i and 6k. This coil unit is also available as a stator, rotor, and an armature. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to coils and coil units used in motors and generators, manufacturing jigs for manufacturing them, manufacturing methods thereof, and rotors, stators, and transformers using the same.

  2. Description of the Related Art In recent years, an electric motor used for an electric vehicle or a hybrid vehicle is composed of a cylindrical stator coil, a columnar rotor arranged inside the stator coil, and a shaft connected to the rotor. . As this stator coil, there is one that is configured by winding a winding wire from the radially inner side of the stator core to the inner teeth of the stator tooth core having an internal tooth shape. Further, a winding device that automatically winds this winding on the inner teeth of the stator iron core has been proposed (see, for example, Patent Document 1).

  FIG. 42 is a structural perspective view of a conventional stator created by the winding device described in Patent Document 1. FIG. FIG. 43 is a partially enlarged view of the stator of FIG.

  As shown in FIG. 42, the conventional stator 120 is a three-phase, eight-pole distributed-type stator. The stator 120 has a stator iron core 130 having 48 teeth (inner teeth) 131 and slots 132 in a ring shape in plan view. Stator 120 has eight U-phase coils 151, V-phase coils 161, and W-phase coils 171, respectively.

  As shown in FIG. 43, each coil unit is arranged in the order of the U-phase coil 151, the V-phase coil 161, and the W-phase coil 171 from the outer periphery of the stator core 130 toward the central axis 130X. In addition, the transition portions 152 and 162 of the U-phase coil 151 and the V-phase coil 161 are arranged from the outer periphery of the stator core so that the three types of coils do not interfere with each other.

  FIG. 44 is a configuration diagram of the winding device described in Patent Document 1. As shown in FIG. 44, the winding device 1100 includes a stator holding portion 1151 that holds the stator core 130, a strand discharge device 1110, and an arm 1220 for pushing the strand into the slot 132 of the stator core 130. ing. FIG. 45 is a configuration diagram of the wire discharge device 1110. As shown in FIG. 45, the strand discharge device 1110 has a linear nozzle 1113 that discharges strands forming a U-phase, V-phase, or W-phase coil in a row in the direction of the slot 132. A first roller 1114 and a second roller 1115 having axes in a direction orthogonal to the longitudinal direction of the linear nozzle 1113 are installed. The strands 140 are supplied in two groups from above the strand discharge device 1110, and are arranged and discharged in one row via a roller.

  FIG. 46 is an enlarged view of a stator in which only the U-phase coil 151 is arranged.

The strands 140 arranged in a row discharged from the linear nozzle 1113 of the strand discharge device 1110 are inserted into a predetermined slot 132a. The strand 140 is wound around the slot 132a and the corresponding slot 132b by the vertical movement of the strand discharge device 1110 and the rotation of the stator holding portion 1151. Furthermore, the element wire 140 is pushed into the slots 132a and 132b by the arm 1220, and the connecting portion 152 does not interfere with the V-phase coil 161 and the W-phase coil 171 to be formed later, so that the outer peripheral side of the stator core 130 More arranged.
JP 2004-194435 A

  In the above-described winding apparatus of Patent Document 1, the strands discharging apparatus 1110 discharges the strands 140 arranged in a line by changing the arrangement direction of the strands 140 with rollers 1114 and 1115. When 140 is a square wire, a flat wire, etc., it was not applicable.

  Further, the U-phase coil transition portion 152 and the V-phase coil transition portion 162 are arranged from the outer peripheral side of the stator core 130 by the operation of the arm 1220. However, when the strand 140 is a flat wire or the like, it is difficult to arrange the strands in a certain direction such as a thickness direction or a width direction, and the space factor is reduced. Thus, in the winding device of Patent Document 1, it is difficult to form a coil in the case of a square wire, a flat wire, or the like.

  In view of the above problems, the object of the present invention is to improve the space factor, or not only the shape of the wire, but also a coil, coil unit, stator, And a rotor, a coil and a coil unit manufacturing jig, and a coil and a coil unit manufacturing method.

In order to achieve the above object, the first present invention provides:
A coil having a shape having at least two sets of two opposing sides, formed by winding a single wire,
Of the two opposing sides, one is the first side and the other is the third side,
Of the other two opposite sides, one is the second side and the other is the fourth side,
The first side, the second side, the third side, and the fourth side are arranged in order based on the direction in which the wire is wound,
In each of the first side and the third side of the two sets, the stacking directions specified by the beginning and end of the wire rod are substantially the same direction.
Each of the specified stacking directions in the second and fourth sides of the other pair of the two sets is a coil that is different from the one set of stacking directions.

The second aspect of the present invention is
In the coil according to the first aspect of the present invention, the stacking directions of the second side and the fourth side are the same as each other and are substantially opposite to the one set of stacking directions.

The third aspect of the present invention
The stacking directions of the second side and the fourth side are different from each other in the coil according to the first aspect of the present invention.

The fourth aspect of the present invention is
In the coil of the third aspect of the present invention, the stacking directions of the second side and the fourth side are substantially opposite to each other and are substantially perpendicular to the set of stacking directions. is there.

The fifth aspect of the present invention is
The respective stacking directions in the second side and the fourth side are as follows:
The coil according to the third aspect of the present invention has a direction larger than 90 degrees and smaller than 180 degrees with respect to the set of stacking directions.

The sixth aspect of the present invention
The said wire is a coil of 1st this invention which is a flat wire.

The seventh aspect of the present invention
The rectangular wire is the coil of the sixth aspect of the present invention laminated in the thickness direction of the rectangular wire.

Further, the eighth aspect of the present invention is
The flat wire is the coil according to the sixth aspect of the present invention, wherein the thickness and the width continuously change in the length direction.

The ninth aspect of the present invention provides
The rectangular wire is the coil of the sixth aspect of the present invention having the same cross-sectional area at an arbitrary position in the length direction.

The tenth aspect of the present invention is
The coil unit according to any one of the first to ninth aspects is a coil unit in which a plurality of coils are continuously connected.

The eleventh aspect of the present invention is
Each of the first sides of the plurality of coils is disposed such that surfaces of the first sides are adjacent to each other.
Each of the third sides of the plurality of coils is arranged such that surfaces of the third sides are adjacent to each other.
When viewed from the vertical direction of the side surface of the second side, each of the first side and the third side in the plurality of coils is substantially in the same direction as the stacking direction of the wires of the first side and the third side. Are located in
The side surfaces of each of the second sides of the plurality of coils are continuously connected between the coils, and at least some of them overlap each other.
When viewed from the vertical direction of the side surface of the fourth side, at least a part of the side surfaces of the fourth side of the plurality of coils overlaps each other between the continuously connected coils. It is a coil unit of this invention.

The twelfth aspect of the present invention is
In the coil unit according to the eleventh aspect of the present invention, the number of laminations of the wire rods in the first side and the third side of all the plurality of coils is the same.

The thirteenth aspect of the present invention is
The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
In the coil unit according to the eleventh aspect of the present invention, a width of the wire in a direction perpendicular to a stacking direction of the wires in the first side and the third side is equal to or less than a width of the slot.

The fourteenth aspect of the present invention is
The first side and the third side are the coil units inserted into slots of a rotor disposed inside a substantially cylindrical stator,
In the coil unit according to the eleventh aspect of the present invention, a width of the wire in a direction perpendicular to a stacking direction of the wires in the first side and the third side is equal to or less than a width of the slot.

The fifteenth aspect of the present invention is
The first side and the third side are the coil units that are inserted into slots of a stator disposed inside a substantially cylindrical outer rotor,
In the coil unit according to the eleventh aspect of the present invention, a width of the wire in a direction perpendicular to a stacking direction of the wires in the first side and the third side is equal to or less than a width of the slot.

  Note that the second side and the fourth side in the coil unit according to any one of the thirteenth to fifteenth aspects of the present invention may be substantially curved along the circumferential shape of the stator or the rotor. In the coil unit according to any one of the thirteenth to fifteenth aspects, the length direction of the wire on the first side and the length direction of the wire on the third side are parallel to each other, and the central axis of the stator It may be arranged so as to be parallel to. In the coil unit according to any one of the thirteenth to fifteenth aspects, the length direction of the wire on the first side and the length direction of the wire on the third side are parallel to each other, and the central axis of the stator May be arranged so as to have a predetermined angle with respect to. Further, the interval between the adjacent slots is narrowed toward the central axis of the stator, and the stacking direction of the first side and the third side is mounted so as to be directed toward the central axis side. The interval between the stacking direction of the first side and the stacking direction of the third side may be narrowed toward the central axis of the stator so as to match the interval between the adjacent slots.

The 16th aspect of the present invention is
A shape having at least a set of two opposing sides formed by winding one wire, one of the two opposing sides being a first side and the other being a third side, Of the two opposite sides, one is the second side and the other is the fourth side, and the first side, the second side, the third side, and the fourth side are based on the direction in which the wire is wound Are coil manufacturing jigs for manufacturing coils, which are arranged in order,
A first groove for laminating the wire and forming the first side, a second groove for laminating the wire and forming the second side, and laminating the wire to form the third side A third groove for laminating and a fourth groove for laminating the wire and forming the fourth side, comprising a jig body arranged in order along the direction of winding the wire,
The direction toward the bottom surface of each of the first groove and the third groove is substantially the same direction.
The direction toward the bottom surface of each of the second groove and the fourth groove is different from the direction toward the bottom surfaces of the first groove and the third groove.
Both ends of each groove in the length direction are coil manufacturing jigs that are open.

The seventeenth aspect of the present invention is
The direction toward the bottom surface of each of the second groove and the fourth groove is substantially the same direction.
The coil manufacturing jig according to the sixteenth aspect of the present invention, which is in a direction substantially opposite to a direction toward the bottom surface of the first groove and the third groove.

The 18th aspect of the present invention is
The coil manufacturing jig according to the sixteenth aspect of the present invention, wherein the directions toward the bottom surfaces of the second groove and the fourth groove are different from each other.

The nineteenth aspect of the present invention
The directions toward the bottom surfaces of the second groove and the fourth groove are opposite to each other.
The coil manufacturing jig according to the eighteenth aspect of the present invention, which is substantially perpendicular to a direction toward the bottom surface of the first groove and the third groove.

The twentieth aspect of the present invention is
The direction toward the bottom surface of each of the second groove and the fourth groove is greater than 90 degrees and smaller than 180 degrees with respect to the direction toward the bottom surfaces of the first groove and the third groove. It is a coil manufacturing jig of the 18th aspect of the present invention.

The 21st aspect of the present invention provides
Of the first to fourth grooves, the side wall of at least one of the grooves is a coil manufacturing jig according to the sixteenth aspect of the present invention, which is detachable from the jig body.

The twenty-second aspect of the present invention provides
(1) A plurality of coils having a shape having at least two sets of two opposing sides formed by winding one wire are continuously connected, and (2) Of the two opposing sides, One is a first side and the other is a third side. (3) Of the two opposite sides, one is a second side and the other is a fourth side. (4) The first side and the second side. A coil unit manufacturing jig for manufacturing a coil unit, wherein the side, the third side, and the fourth side are sequentially arranged based on a direction in which the wire is wound,
A first groove for laminating the wire and forming the first side, a second groove for laminating the wire and forming the second side, and laminating the wire to form the third side A third groove for laminating and a fourth groove for laminating the wire and forming the fourth side, comprising a jig body arranged in order along the direction of winding the wire,
The directions toward the bottom surfaces of the first groove and the third groove are substantially the same direction,
The directions toward the bottom surfaces of the second groove and the fourth groove are different from the directions toward the bottom surfaces of the first groove and the third groove,
Each width in the second groove and the fourth groove is a length capable of arranging the plurality of wires in parallel in the width direction,
Both ends of each groove in the length direction are coil unit manufacturing jigs that are open.

The twenty-third aspect of the present invention provides
The depths of the second groove and the fourth groove are larger than the product of the maximum number of layers of each of the plurality of coils and the width of the wire in the stacking direction,
The depth of each of the first groove and the third groove is greater than the product of the number of all the coils stacked and the width of the wire in the stacking direction. It is.

The twenty-fourth aspect of the present invention provides
In the coil unit manufacturing jig according to the 22nd aspect of the present invention, one side wall of the second groove and / or the fourth groove is movable so that the groove width can be adjusted.

The twenty-fifth aspect of the present invention provides
Of the first groove to the fourth groove, the side wall of at least one groove is the coil unit manufacturing jig according to the 22nd aspect of the present invention, which is detachable from the jig body.

The twenty-sixth aspect of the present invention provides
All or a part of one side wall of the second groove and the fourth groove is a coil unit manufacturing jig according to a twenty-second aspect of the present invention, which is a side surface of the second side of the coil formed immediately before.

The twenty-seventh aspect of the present invention provides
A coil unit manufacturing jig according to a twenty-second aspect of the present invention, comprising a removable spacer that forms one side wall of the second groove and / or the fourth groove.

The twenty-eighth aspect of the present invention provides
A coil manufacturing method using the coil manufacturing jig of any of the 16th to 21st aspects of the present invention,
The wire is disposed from an arbitrary position of any one of the first to fourth grooves, and is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, Arranged from the other open end of the groove to the next groove through one open end of the next groove, and from the other open end of the groove to the next groove through the one open end of the next groove And a coil manufacturing method comprising a step of repeating a squeezing step of disposing from the other open end of the groove through the one open end of the predetermined groove to a position before the arbitrary position of the predetermined groove a predetermined number of times It is.

The 29th aspect of the present invention provides
The wire is a flat wire,
Arranging the wire in any one of the first to fourth grooves is to arrange the bottom surface of the groove and the surface having the width of the rectangular wire to face each other.
When the wire is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, the wire rod is twisted or after being twisted, The coil manufacturing method according to the twenty-eighth aspect of the present invention is arranged so that a bottom surface and a surface having a width of the rectangular wire face each other.

The 30th aspect of the present invention
The predetermined groove is the first groove,
The predetermined number of scouring steps are:
A coil manufacturing method according to a twenty-eighth aspect of the present invention, which is a step of performing at least the arrangement of the wire rod in the third groove.

The thirty-first aspect of the present invention
A coil unit manufacturing method using the coil unit manufacturing jig of any one of the 22nd to 27th aspects of the present invention,
The wire is disposed from an arbitrary position of any one of the first to fourth grooves, and is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, Arranged from the other open end of the groove to the next groove through one open end of the next groove, and from the other open end of the groove to the next groove through the one open end of the next groove And a coil manufacturing step including a step of repeating a squeezing step of disposing from the other open end of the groove through one open end of the predetermined groove to a position before the arbitrary position of the predetermined groove a predetermined number of times. A unit repetition step that repeats the number of times corresponding to the number of the plurality of coils,
The squeezing step in the next coil manufacturing step after the coil manufacturing step is adjacent to the second side and the fourth side of the coil formed in the coil manufacturing step in the second groove and the fourth groove. The coil unit manufacturing method is a step of arranging the wire.

The thirty-second invention of the present invention
After the coil manufacturing step, when the next coil manufacturing step is performed, the side wall is moved to further secure the width of the second side and / or the fourth side for the next coil. The thirty-first coil unit manufacturing method of the present invention.

The thirty-third aspect of the present invention provides
The coil unit manufacturing method according to the thirty-first aspect of the present invention, further comprising a removal step of removing the one side wall and removing the wound wire after the unit repetition step.

The 34th aspect of the present invention provides
The coil unit manufacturing method according to the thirty-first aspect of the present invention, further comprising a step of inserting the spacer when performing the next coil manufacturing step after the coil manufacturing step.

The 35th aspect of the present invention provides
After the coil manufacturing step, a thirty-fourth book further comprising the step of securing the second groove and / or the fourth groove for the next coil including the width of the spacer by moving the side wall. It is a coil unit manufacturing method of invention.

The thirty-sixth aspect of the present invention provides
A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
A stator comprising the coil unit of the thirteenth aspect of the present invention, wherein the first side and the third side are each inserted into two slots, and are attached to the core.

The thirty-seventh aspect of the present invention provides
A rotor core having a plurality of cores and slots disposed inside a substantially cylindrical stator core;
The first side and the third side each include a coil unit according to a fourteenth aspect of the present invention that is mounted on the core by being inserted into two slots.

The thirty-eighth aspect of the present invention provides
A stator core having a plurality of cores and slots disposed inside a substantially cylindrical outer rotor;
The first side and the third side each include a coil unit according to a fifteenth aspect of the present invention, which is attached to the core by being inserted into two slots.

The 39th aspect of the present invention provides
A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
A coil unit of the eleventh aspect of the present invention used as a U-phase coil unit, wherein the coils of the second aspect of the present invention are connected;
A coil unit of the eleventh invention used as a V-phase coil unit, in which the coils of the fifth invention are connected;
A coil unit of the eleventh invention used as a W-phase coil unit, in which the coils of the fourth invention are connected,
The W-phase coil unit, the U-phase coil unit, and the V-phase coil unit are attached to the core by inserting each of the first side and the third side into the slot,
The direction in which the wires on the second side and the fourth side of the V-phase coil unit overlap is a stator formed so as not to interfere with the U-phase coil unit and the W-phase coil unit.

The 40th aspect of the present invention
Each of the coils in the plurality of coils has a stacking direction in each of the second side and the fourth side that is substantially opposite to each other and is substantially perpendicular to the set of stacking directions. And
The side surface of the second side is adjacent between the continuously connected coils,
The side surface of the fourth side is the coil unit according to the eleventh aspect of the present invention, which is adjacent between the continuously connected coils.

The 41st aspect of the present invention provides
In the 40th aspect of the present invention, each of the second side and the fourth side of the plurality of coils is disposed from one surface of the first side of the coil unit or from the other surface. It is a coil unit.

The forty-second aspect of the present invention provides
Each of the second side and the fourth side of the plurality of coils is the coil unit according to the 40th aspect of the present invention, which is arranged from the coil at the center of the first side of the coil unit.

The 43rd aspect of the present invention provides
The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
The width of the wire in the direction perpendicular to the stacking direction of the wires in each of the first side and the third side is equal to or less than the width of the slot;
The second side and the fourth side are a coil unit according to a 41st aspect of the present invention, which is disposed from the outer peripheral side of the stator.

The 44th aspect of the present invention provides
The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
The width of the wire in the direction perpendicular to the stacking direction of the wires in each of the first side and the third side is equal to or less than the width of the slot;
The second side and the fourth side are the coil units according to the 41st aspect of the present invention, which are arranged from the inner peripheral side of the stator.

The 45th aspect of the present invention provides
A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
A coil unit of the forty-third invention used as a U-phase coil unit;
A coil unit of the forty-second invention used as a V-phase coil unit;
A coil unit of the forty-fourth present invention used as a W-phase coil unit,
The U-phase coil unit, the V-phase coil unit, and the W-phase coil unit are attached to the core by inserting the first side and the third side into the slot,
The U-phase coil unit is disposed from the outer peripheral side of the stator, the W-phase coil unit is disposed from the inner peripheral side of the stator, and the V-phase coil unit includes the U-phase coil unit and the V-phase coil unit. Between the phase coil units,
In the stator, the heights of the second side and the fourth side of the U-phase coil unit, the V-phase coil unit, and the W-phase coil unit are the same.

  According to the present invention, the coil, the coil unit, the stator, and the rotor, the coil, and the coil unit that can further improve the space factor or can be manufactured more easily without being limited to the shape of the wire. A manufacturing jig, a coil and a coil unit manufacturing method can be provided.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
Below, while explaining the structure of the U-phase coil unit in Embodiment 1 which is an example of the coil unit of this invention, the example of the coil of this invention is also demonstrated simultaneously.

  FIG. 1 is a perspective view of a U-phase coil unit according to Embodiment 1 of the present invention. 2A to 2D show a front view, a top view, a right side view, and a left side view of the U-phase coil unit shown in FIG. 1, respectively. Here, in each coordinate axis of FIGS. 1 and 2A to 2D, the X axis + direction is the right direction of the U-phase coil unit 1, the Y axis + direction is the upward direction, and the Z axis + direction is the depth. Shows direction. The same applies to other drawings shown below.

  As shown in FIG. 1, the U-phase coil unit 1 according to the first embodiment is configured by winding a single flat wire 2, and includes a winding start portion 3 and a winding end portion 4 of the flat wire 2. I have. Moreover, as shown in the front views of FIGS. 1 and 2A, the U-phase coil unit 1 has a substantially rectangular shape when viewed from the front, and includes a central space 5 of the twisted rectangular wire 2. It is configured to be turned counterclockwise from the starting portion 3. 2A, the U-phase coil unit 1 includes a first side 1a located on the X-axis-direction side of the central space 5, a second side 1b located on the Y-axis-direction side, X A third side 1c located on the axis + direction side and a fourth side 1d located on the Y axis + direction side are provided.

  Further, the U-phase coil unit 1 includes a bent portion 1e that connects the first side 1a and the second side 1b, and includes a second side 1b, a third side 1c, a fourth side 1d, Bending portions 1f, 1g, and 1h that connect the one side portion 1a are provided. The second side 1b and the fourth side 1d are disposed in the Z-axis direction with respect to the first side 1a and the third side 1c.

  Further, the flat wire 2 has a thickness 2t and a width 2w as shown in the enlarged view of the portion p in FIG. As shown in FIG. 1, the flat wire 2 has a surface having a width 2w in the first side 1a, the second side 1b, the third side 1c, and the fourth side 1d. It is arranged to face.

The first side 1a and the third side 1c have a plurality of rectangular wires 2 stacked in the thickness 2t direction of the rectangular wire 2. With reference to the winding direction of the flat wire 2 from the winding start portion 3 to the winding end portion 4, the stacking direction of the flat wire 2 in the first side portion 1a is the first direction 1i, and the stacking direction in the third side portion 1c is the first direction. Let it be 1k in 3 directions. Then, as shown in FIG. 2B, the first direction 1i is inclined by θ ₁ degree with respect to the Z axis + direction and in the X axis + direction, and the third direction 1k is in the Z axis + direction. In contrast, it is tilted in the X-axis direction by θ ₁ degree.

Further, as shown in FIG. 2B, the second side 1b and the fourth side 1d are curved so as to swell in the Z-axis direction. Further, the second side portion 1b, as shown in FIG. 2 (a), Y axis - is composed of four sides 1b ₁ ～1B ₄ arranged in this order in the direction. The fourth side portion 1d is also composed of _four side portions 1d _{1 to} 1d ₄ arranged in order in the Y axis + direction. As will be described in detail later, the stacking directions of the rectangular wires 2 in the _four sides 1b _{1 to} 1b 4 of the second side 1b are the same as shown in FIGS. 2 (c) and (d). There is a second direction 1j. In addition, the stacking direction of each of the rectangular wires 2 in the _four side portions 1d _{1 to} 1d ₄ of the fourth side portion 1d is also the same direction, which is the fourth direction 1l. The second direction 1j is inclined by θ ₂ degrees and the Y axis + direction with respect to the Z axis − direction, and the fourth direction 1l is inclined by θ ₂ degrees and the Y axis − direction with respect to the Z axis − direction. (See FIG. 3).

The U-phase coil unit 1 according to the first embodiment includes a first coil 6 including the side part 1b ₁ and the side part 1d ₁ , a second coil 7 including the side part 1b ₂ and the side part 1d ₂ , and a side part. The third coil 8 including 1b ₃ and the side portion 1d ₃ and the fourth coil 9 including the side portion 1b ₄ and the side portion 1d ₄ are provided.

  The coil will be described below.

  FIG. 3 is a perspective view in which the intervals of the coils of the U-phase coil unit according to the first embodiment of the present invention are intentionally separated for explanation. 4A and 4B show a top view and a side view of the U-phase coil unit shown in FIG. FIG. 47 is a perspective view of the first coil of the U-phase coil unit according to the first embodiment.

  As shown in FIGS. 3, 4 (a) and 4 (b), the winding start portion 3 is disposed on the first coil 6. Then, the first coil 6, the second coil 7, the third coil 8, and the fourth coil 9 are formed in this order as the flat wire 2 is wound around from the starting portion 3. Further, the winding end portion 4 is disposed in the fourth coil 9. Note that the number of turns of the flat wire 2 in each coil in the first embodiment (hereinafter referred to as the number of turns) is nine.

  Each coil has a rectangular shape when viewed from the Z-axis direction. 47, the first coil 6 includes a first side 6a located on the X axis-direction side of the central space 5, a second side 6b located on the Y axis-direction side, and the X axis + direction. It has a third side portion 6c located on the side and a fourth side portion 6d located on the Y axis + direction side. Similarly, as shown in FIG. 3 and FIGS. 4A and 4B, the second coil 7 includes a first side 7a, a second side 7b, a third side 7c, and a fourth side. 7d, the third coil 8 includes a first side 8a, a second side 8b, a third side 8c, and a fourth side 8d, and the fourth coil 9 includes the first side 9a, Two side portions 9b, a third side portion 9c, and a fourth side portion 9d are provided.

  As shown in FIG. 47, a bent portion 6e is formed between the first side 6a and the second side 6b of the first coil 6, and similarly, the second side 6b and the third side 6b. Bent portions 6f, 6g, and 6h are formed between the side portion 6c, the fourth side portion 6d, and the first side portion 6a. As shown in FIG. 3, the second to fourth coils 7, 8, and 9 are similarly bent.

  Moreover, since each coil is comprised by 9 turns, these 1st-4th side parts and a bending part become a structure by which the nine flat wires 2 were laminated | stacked, respectively.

  Next, the positional relationship of each side part between the coils will be described.

  As shown in FIGS. 1 to 4, the first side portions 6 a, 7 a, 8 a, and 9 a are arranged so as to substantially overlap each other in the Z axis + direction in order, and the third side portions 6 c, 7 c, and 8 c are disposed. 9c are also arranged so as to substantially overlap each other in the + Z-axis direction. The second sides 6b, 7b, 8b, and 9b are arranged so as to substantially overlap each other in the Y-axis direction, and the fourth sides 6d, 7d, 8d, and 9d are substantially sequentially arranged in the Y-axis + direction. Is placed on top of each other.

Here, the four sides 1b ₁ , 1b ₂ , 1b ₃ , 1b _{4 of} the second side 1b described in FIG. 2 are respectively connected to the second sides 6b, 7b, 8b, 9b of each coil in FIG. Equivalent to. Further, the side portions 1d ₁ , 1d ₂ , 1d ₃ , 1d ₄ correspond to the fourth side portions 6d, 7d, 8d, 9d of each coil, respectively. That is, the shapes of the first coil 6 to the fourth coil 9 increase in order in the Y-axis direction and the Z-axis direction.

  Next, the structure of the coil will be described.

FIG. 5 is a perspective view in which the 1 to 3 turns of the first coil of the U-phase coil unit 1 according to the first embodiment of the present invention are intentionally separated for explanation. 6 (a), 6 (b), and 6 (c) respectively show a front view, a top view, and a left side view of the U-phase coil unit shown in FIG. Each surface of the rectangular wire 2 is shown as a surface 2a, the other surface is a surface 2b, the surface 2a is hatched, and the surface 2b is dotted. Since each coil is composed of 9 turns as described above, FIG first coil 6 as shown in 5 the first side portion 6a of the first side portion 6a of the first turn (see FIG. 3) ₁ And the first side 6a of the _second turn is numbered in order from the first side 6a ₂ to the ninth turn. Incidentally, if not given the first side portion 6a and number of lowercase, first side portion 6a _refers to the entire 6a 1 ~6a _2. Similarly, each side and each coil are also numbered.

The coil structure will be described using the first coil 6 as an example. As shown in FIG. 5, the whirling start portion 3 is connected to the first side portion 6 a ₁ . The flat wire 2 is the first side portion 6a ₁ and the third side portion 6c ₁ , and the surface 2b faces the front (Z-axis-direction) side, and the second side portion 6b ₁ and the fourth side portion 6d ₁ are surfaces. 2a is arranged so as to face the front (Z-axis-direction) side. Then, for example, in the bent portions 6e and 6g, the flat wire 2 extends from the winding start portion 3 to the winding end portion 4 so that the surface 2b faces from the front side (Z axis − direction) side to the back surface (Z axis + direction) side. It is twisted counterclockwise in the lengthwise direction. In the bent portions 6f and 6h, the flat wire 2 is twisted so that the surface 2a faces from the front side to the back side, that is, the surface 2b faces the front side.

  Next, the positional relationship of each side portion from the first turn to the ninth turn will be described.

  Here, the first coil 6 shown in FIG. 3 will be described as an example. The stacking direction of the rectangular wire 2 from the first turn to the ninth turn in each of the first side 6a, the second side 6b, the third side 6c, and the fourth side 6d in the first coil 6 is the first. The direction is 6i, the second direction 6j, the third direction 6k, and the fourth direction 6l.

As shown in FIGS. 4A and 4B, the first direction 6i is inclined by θ ₁ degree from the Z axis + direction and in the X axis + direction. Further, the third direction 6k is inclined by θ ₁ degree from the Z axis + direction and in the X axis − direction. Further, the second direction 6j is inclined by θ ₂ degrees from the Z axis − direction and in the Y axis + direction, and the fourth direction 6l is inclined by θ ₂ degrees from the Z axis − direction and in the Y axis − direction. In other words, the stacking direction 6i in the first side portion 6a and the stacking direction 6k in the third side portion 6c are closer to each other toward the Z axis + direction. Further, the stacking direction 6j in the second side portion 6b and the stacking direction 6l in the fourth side portion 6d are in a relation closer to each other toward the Z-axis direction. Also in the second to fourth coils, the flat wire 2 is laminated in the same lamination direction as each side portion of the first coil 6.

  If this is roughly grasped, in each coil, the lamination direction of the flat wire in the first side portion and the third side portion is substantially the Z axis + direction, and the flat wire in the second side portion and the fourth side portion. It can be said that the stacking direction is substantially the Z-axis minus direction, which is the opposite direction to the Z-axis plus direction.

  In the U-phase coil unit 1 described above, the first direction 1i (see FIG. 2 (b)), the second direction 1j (see FIG. 2 (c)), the third direction 1k (see FIG. 2 (b)), The four directions 11 (see FIG. 2C) are the first direction 6i (see FIG. 4A), the second direction 6j (see FIG. 4B), and the third direction 6k (see FIG. 2) in the first coil 6. 4 (a)), which coincides with the fourth direction 61 (see FIG. 4 (b)).

  Next, the connection between the coils will be described.

Flat wire 2 as shown in FIG. 5, started Maki from the first side portion 6a _1, the second side portion 6b _1, the third side portion 6c _1, first by forming the fourth side portion 6d ₁ and the forward A first turn of the coil 6 is formed. The first side 6a _{2 of} the second turn is formed on the Z axis + direction side of the first side 6a ₁ , and the second side 6b ₂ is on the Z axis − direction side of the second side 6b _1. Formed. In FIG. 5, the second side portion 6b and the fourth side portion 6d appear to be arranged in the Z-axis + direction, but for the sake of explanation, each turn is drawn to the front side in the drawing. This is because it represents a state.

Subsequently, the third side portion 6c ₂ is formed on the Z axis + direction side of the third side portion 6c ₁ , and the fourth side portion 6d ₂ is formed on the Z axis − direction side of the fourth side portion 6d _1. The Similarly, the fourth side 6d _{9 of} the ninth turn is formed.

As shown in FIG. 3, the first side portion 7 a ₁ of the first turn of the second coil 7 is formed following the fourth side portion 6 d ₉ of the ninth turn of the first coil 6. In addition, the second coil 7 is formed. The coils are seamlessly connected by the fourth side of the ninth turn of the coil and the first side of the first turn of the next coil. The fourth side portion 9d ₉ of the fourth turn 9 of the fourth coil 9 and the winding end portion 4 are continuously connected.

Note that θ ₁ degree described above is aligned with a slot of a stator, which will be described later. Therefore, there is no strict limitation on θ ₁ degree, and the first direction 1i and the third direction 1k are substantially in the Z axis + direction. All you have to do is. As will be described in detail later, the above-described θ ₂ degrees only needs to be an angle that does not interfere with the stator, and the second direction 1j and the fourth direction 11 are substantially the Z-axis direction. Good.

  That is, the first direction 1i and the third direction 1k, the second direction 1j, and the fourth direction 11 are substantially opposite directions. The first direction and the third direction, and the second direction and the fourth direction in each of the first coil 6 to the fourth coil 9 are also substantially opposite directions.

  Next, the correspondence between the present invention and the first embodiment will be briefly described.

  The first side, the second side, the third side, and the fourth side of the present invention are, for example, the first side 6a, the second side 6b, and the third side of the first coil 6 of the first embodiment. It corresponds to the side part 6c and the fourth side part 6d.

  Further, according to the present invention, “the respective lamination directions specified by the beginning and end of the wire in the first side and the third side of the set are substantially the same direction as each other”. Corresponds to, for example, that the first direction 6i and the third direction 6k of the first embodiment are substantially the same direction.

  In the present invention, “the respective laminating directions on the second side and the fourth side are substantially the same as each other and substantially opposite to the one set of laminating directions” In contrast to the first direction 6i and the third direction 6k that are substantially the same direction of the first embodiment being the Z axis + direction, the second direction 6j and the fourth direction 6l that are substantially the same direction are Z. This corresponds to the axial direction.

  Further, the aspect of the present invention refers to, for example, the surface located on the Y axis + and − side of the fourth side portion 6d formed by the end surface having the thickness 2t of the plurality of rectangular wires 2 in the first embodiment. It corresponds to.

  In addition, the surface of the present invention is the surface of the stacked side portions, for example, the first side formed by the surface having the width 2w of the flat wire 2 in the first coil 6 of the first embodiment. It corresponds to the surface located on the Z axis − side and + side of the portion 6a.

  Further, in the present invention, “the first sides of the plurality of coils are arranged such that the surfaces of the first sides are adjacent to each other”, for example, in the first embodiment The first direction 6i is substantially the Z axis + direction, and the first sides 6a, 7a, 8a, and 9a are also substantially sequentially arranged in the Z axis + direction.

  Further, in the present invention, “the third sides of the plurality of coils are arranged so that the surfaces of the third sides are adjacent to each other” means, for example, in the first embodiment. The third direction 6k is substantially the Z axis + direction, and the third sides 6c, 7c, 8c, and 9c correspond to the substantially Z axis + direction in order.

  Also, according to the present invention, “when viewed from the vertical direction of the side surface of the second side, the side surfaces of the second side of the plurality of coils are at least partially overlapped between the coils.” For example, in the first embodiment, the second sides 6b, 7b, 8b, 9b are sequentially arranged in the Y-axis-direction, so that the Y-axis is the direction perpendicular to the side surface of the second side 6b. When viewed from the direction, this corresponds to the fact that the side surfaces of the second side portions of the first to fourth coils substantially overlap in the Y-axis direction (see FIGS. 2 and 3).

  Further, according to the present invention, “when viewed from the vertical direction of the side surface of the second side, the side surfaces of the fourth side of the plurality of coils are at least partially overlapped with each other between the coils.” For example, in the first embodiment, the fourth sides 6d, 7d, 8d, and 9d are sequentially arranged in the Y axis + direction, so that the Y axis that is the vertical direction of the side surface of the fourth side 6d When viewed from the direction, this corresponds to the fact that the side surfaces of the fourth side portions of the first to fourth coils substantially overlap in the Y-axis direction (see FIGS. 2 and 3).

(Embodiment 2)
The structure of the V-phase coil unit according to the second embodiment, which is an example of the coil unit of the present invention, will be described below, and an example of the coil of the present invention will be described at the same time.

  FIG. 7 is a perspective view of the V-phase coil unit according to the second embodiment of the present invention. 8A to 8D respectively show a front view, a top view, a right side view, and a left side view of the V-phase coil unit shown in FIG.

  FIG. 9 is a perspective view in which the intervals of the coils of the V-phase coil unit according to the second embodiment of the present invention are intentionally separated for explanation. FIGS. 10A and 10B show a top view and a left side view of the V-phase coil unit shown in FIG. FIG. 48 is a perspective view of the first coil of the V-phase coil unit according to the second embodiment.

  FIG. 11 is a perspective view intentionally separated for the sake of explanation of the interval of 1 to 3 turns of the first coil of the V-phase coil unit according to the second embodiment of the present invention. FIGS. 12A, 12B, and 12C are respectively a front view, a top view, and a left side view of the V-phase coil unit shown in FIG.

  As shown in FIGS. 7 to 12 and FIG. 48, the V-phase coil unit 11 has the same basic configuration as the U-phase coil unit 1 of the first embodiment described above. The stacking direction of the flat wire 2 on the second side and the fourth side of the unit 11 is different from that of the first embodiment. Therefore, this difference will be mainly described. In addition, the code | symbol which shows each part in the V-phase coil unit 11 shall add 10 to the code | symbol which shows each part of the U-phase coil unit 1. FIG. In addition, description of the code | symbol of the V-phase coil unit 11 was abbreviate | omitted about the fundamentally common part in the V-phase coil unit 11 and the U-phase coil unit 1. FIG.

As shown in FIGS. 8 and 10, the first direction 16 i and the third direction 16 k of the first coil 16 of the V-phase coil unit 11 are the first direction 6 i of the first coil 6 of the U-phase coil unit 1. And the third direction 6k is the same direction. Then, the second direction 16j is, Z-axis - theta ₃ times Y axis to the direction - are inclined in the direction, the fourth direction 16l is, Z-axis - inclined theta ₃ times Y axis with respect to the direction + direction Yes. The first to fourth directions in the first to fourth coils are the same direction.

In the V-phase coil unit 11 according to the second embodiment of the present invention, the second direction 11j is the same as the second direction 16j of the first coil 16, and θ ₃ degrees Y-axis with respect to the Z-axis-direction. -Inclined in the direction. The fourth direction 11l is the same as the fourth direction 16l of the first coil 16, the Z-axis - the direction is inclined to the theta ₃ times Y-axis + direction.

Further, θ ₃ degrees is obtained by using the U-phase coil unit 1 according to the first embodiment, the V-phase coil unit 11 according to the second embodiment, and the W-phase coil unit 21 according to the third embodiment to be described later. Is an angle that does not interfere with other U-phase coil unit 1 and W-phase coil unit 21, and θ ₃ can take a value that is larger than 0 degree and smaller than 90 degrees. .

  That is, the second direction 11j and the fourth direction 11l are different directions, and are 90 degrees (Y axis + direction or Y axis) with respect to the Z axis + direction, which is substantially the same direction as the first direction 11i and the third direction 11k. − Direction) and smaller than 180 degrees (Z axis − direction) with respect to the Z axis + direction. Further, the second direction and the fourth direction in each of the coils from the first coil 16 to the fourth coil 19 are also different directions, and are 90 degrees with respect to the Z axis + direction which is substantially the same direction as the first direction and the third direction. The direction is larger than the angle and smaller than 180 degrees.

  Next, the correspondence between the present invention and the second embodiment will be briefly described.

  In the present invention, “the respective laminating directions on the second side and the fourth side are directions larger than 90 degrees and smaller than 180 degrees with respect to the one set of laminating directions” means, for example, In the second embodiment, the second direction 16j and the fourth direction 16l are 90 degrees (Y axis + direction or Y axis −) with respect to the Z axis + direction which is substantially the same direction as the first direction 16i and the third direction 16k. This corresponds to a direction that is larger than the direction (Z direction) and smaller than 180 degrees (Z axis-direction) with respect to the Z axis + direction.

(Embodiment 3)
Hereinafter, the structure of the W-phase coil unit according to Embodiment 1, which is an example of the coil unit of the present invention, will be described, and an example of the coil of the present invention will also be described.

  FIG. 13 is a perspective view of a W-phase coil unit according to Embodiment 3 of the present invention. FIGS. 14A to 14D respectively show a front view, a top view, a right side view, and a left side view of the W-phase coil unit shown in FIG.

  FIG. 15 is a perspective view in which the intervals of the coils of the W-phase coil unit according to the third embodiment of the present invention are intentionally separated for explanation. FIGS. 16A and 16B show a top view and a left side view of the W-phase coil unit shown in FIG. FIG. 49 is a perspective view of the first coil of the W-phase coil unit according to the third embodiment.

  FIG. 17 is a perspective view intentionally separated for the sake of explanation of the interval of 1 to 3 turns of the first coil of the W-phase coil unit according to the third embodiment of the present invention. 18A, 18B, and 18C are respectively a front view, a top view, and a left side view of the U-phase coil unit shown in FIG.

  As shown in FIGS. 13 to 18 and 49, the W-phase coil unit 21 has the same basic configuration as the U-phase coil unit 1 described above, but the second phase of the U-phase coil unit 1 is the same. The stacking direction of the flat wire 2 at the side portion and the fourth side portion is different from that of the first embodiment. Therefore, this difference will be mainly described. In addition, the code | symbol which shows each part in the W-phase coil unit 21 shall add 20 to the code | symbol which shows each part of a U-phase coil unit. In addition, description of the code | symbol of the W-phase coil unit 21 was abbreviate | omitted about the part which is fundamentally common in the W-phase coil unit 21 and the U-phase coil unit 1.

  As shown in FIGS. 14 and 16, the first direction 26 i and the third direction 26 k in the first coil 26 of the W-phase coil unit 21 are the first direction of the first coil 6 of the U-phase coil unit 1. 6i and the third direction 6k are in the same direction. The second direction 26j is substantially the Y axis + direction, and the fourth direction 26l is substantially the Y axis-direction. That is, the second direction 26j and the fourth direction 26l of the first coil 26 of the W-phase coil unit 21 are opposite directions, with respect to the Z axis + direction, which is substantially the same direction as the first direction 26i and the third direction 26k. The vertical direction. The first to fourth directions in the first to fourth coils are the same direction.

  In the W-phase coil unit 21 according to the third embodiment of the present invention, the second direction 21j is the same as the second direction 26j of the first coil 26 and is substantially the Y axis + direction. The fourth direction 21l is the same as the fourth direction 26l of the first coil 26 and is substantially the Y-axis-direction.

  That is, the second direction 21j and the fourth direction 21l of the W-phase coil unit 21 are opposite directions, and are perpendicular to the Z axis + direction, which is substantially the same direction as the first direction 21i and the third direction 21k. ing. Also, in each of the coils from the first coil 26 to the fourth coil 29, the second direction and the fourth direction are substantially opposite directions, and in the Z axis + direction, which is substantially the same direction as the first direction and the third direction. On the other hand, it is perpendicular.

  Next, the correspondence between the present invention and the third embodiment will be briefly described.

  Further, according to the present invention, "the respective laminating directions on the second side and the fourth side are substantially opposite to each other and substantially perpendicular to the set of laminating directions" For example, the second direction 26j and the fourth direction 26l of the third embodiment are substantially opposite directions, and the Z direction + direction is substantially the same direction as the first direction 26i and the third direction 26k. This corresponds to the vertical direction.

Further, “in the other set of the second side and the fourth side, each stacking direction is different from the set of stacking directions” in the present invention means, for example, Embodiment 2. The second direction 16j is different from the first direction 16i and the third direction 16k, which are substantially the same, and the fourth direction 16l is also a different direction. The second direction 16j and the fourth direction 16l are shifted by θ ₃ degrees with respect to the Z-axis direction, but the angles of the second direction 16j and the fourth direction 16l with respect to the Z-axis direction may be different. For example, the second direction 16j may be the same direction as the second direction 6j of the U-phase coil unit 1, and the fourth direction 16l may be the same direction as the fourth direction of the W-phase coil unit 21.

  Next, a modification of the third embodiment will be described.

  Unlike the U-phase coil unit 1, as shown in FIG. 13, the first side 21a, the second side 21b, and the third side are not the bent portions 21e, 21f, 21g, and 21h of the W-phase coil unit 21. Although the flat wire 2 is twisted in the middle of the portion 21c and the fourth side portion 21d, it may be twisted at the bent portions 21e, 21f, 21g, and 21h.

(Embodiment 4)
Below, the stator in Embodiment 4 concerning this invention using the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21 is demonstrated.

  FIG. 19A is a perspective view of the stator in the fourth embodiment. FIG. 19B and FIG. 19C are a plan view and a side view of the stator shown in FIG. As shown in FIG. 19, the stator according to the fourth embodiment includes eight U-phase coil units 1, V-phase coil units 11, W-phase coil units 21, and a stator core 30.

  FIG. 20A is a top view of the stator core 30. FIG. FIG. 20B is an enlarged view of the r portion shown in FIG. FIG. 20C is a perspective view of the stator core 30. 20A and 20C schematically show each coil unit in order to clarify the positional relationship between the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21. Yes.

  As shown in FIGS. 20A and 20C, the stator core 30 has a substantially cylindrical shape, and 48 teeth 31 are formed on the inner side thereof so as to protrude toward the cylindrical center 30a. have. As shown in the enlarged view of FIG. 20B, the stator core 30 has a slot 32 formed between the teeth 31 and having an insertion port 33 on the center side. At the tips of the teeth 31 in the center 30a direction, flanges 31a are formed on both sides along the circumferential direction. By this flange 31a, the insertion port 33 to the slot 32 located on the center side is narrowed.

  As shown in FIGS. 19A, 19B, and 19C, the U-phase coil unit 1 has a U-phase coil unit in the slot 32 so that the Z-axis + direction coincides with the direction of the center 30a of the stator core 30. The first side portion 1 a and the third side portion 1 c are inserted, and the fourth side portion 1 d is disposed on the upper surface of the stator core 30. Also, as shown in the plan view of FIG. 20 (a), from the eight U-phase coil units 1 arranged on the stator core 30, the U-phase coil unit 1 'and the next coil with reference to the clockwise direction. The coil unit 1 ″ that is a unit will be described as an example. When the center 30a is viewed from the outer peripheral side of the stator core 30, the first side 1a is arranged on the left side and the third side 1c is arranged on the right side. It becomes. The same applies to the V-phase and W-phase coil units.

  As shown in FIG. 20A, the slot into which the first side 1a of the U-phase coil unit 1 is inserted is referred to as a slot 32u, and the slot into which the third side 1c is inserted is referred to as a slot 32u '. To do. Similarly, a slot in which the first side 11a of the V-phase coil unit 11 is inserted is 32v, and a slot in which the third side 11c is inserted is 32v '. Further, the slot in which the first side 21a of the W-phase coil unit 21 is inserted is 32w, and the slot in which the third side 21c is inserted is 32w '.

  These slots are arranged in the order of slots 32u, 32u ′, 32v, 32v ′, 32w, 32w ′, 32u in the clockwise direction, and this arrangement is repeated eight times. Therefore, the slot next to the slot 32u with respect to the clockwise direction is the slot 32u ′, and the fifth slot with respect to the counterclockwise direction is the slot 32u ′. Thus, one U-phase coil unit 1 is inserted into slots 32u and 32u ′ having four slots 32 therebetween. Similarly, the V-phase coil unit 11 and the W-phase coil unit 21 are also inserted and arranged.

  20A, the fourth side 1d of the U-phase coil unit 1, the fourth side 11d of the V-phase coil unit 11, and the fourth side 21d of the W-phase coil unit 21. Each coil unit is inserted into the slot so as to be arranged from the outer periphery of the stator core 30 toward the center in this order. In addition, the second and fourth sides of the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21 of the fourth embodiment are substantially curved along the outer periphery of the stator. .

The first phase 1i, 11i, 21i and the third direction 1k, 11k, 21k Z of the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21 in the first to third embodiments. The angle θ _{1 with} respect to the axis + direction is determined by the angle determined by the number of slots 32.

For example, in the U-phase coil unit 1 according to the first embodiment, the central angle in the stator core 30 between the slot 32u and the slot 32u ′ is twice as large as θ ₁ degree (the angle between the first direction 1i and the third direction 1k). ). Here, in the fourth embodiment, since the three types of coil units are arranged eight by eight, the central angle of the two slots into which each coil unit is inserted is about 37.5 degrees, and θ ₁ is About 18.25 degrees. Thus, θ ₁ degree is determined by the shape of the stator core.

  In the coil units of the first to third embodiments, the winding start portion is connected to the first side portion, and the winding end portion is connected to the fourth side portion. Therefore, the rectangular wires in the first direction and the third direction are used. The number of layers 2 is the same. Since the number of layers is the same, that is, the number of powers, the thickness of the coil unit in the Z-axis direction is constant when inserted into the stator core 30. As a result, the magnetic field intensity generated in the teeth is stabilized and coking can be prevented, which is more preferable. Furthermore, it is more preferable that the U, V, and W phase coil units have substantially the same wire length and resistance value (impedance).

  Next, a modification of the above-described embodiment will be described.

Further, θ ₂ degrees in the U-phase coil unit 1 and θ ₃ degrees in the V-phase coil unit 11 are the second side portion 1b and the fourth side portion 1d of the U-phase coil unit 1 and the second phase portion 1d of the V-phase coil unit 11. It suffices if the angles are such that the two side portions 11b and the fourth side portion 11d, the second side portions 21b and 21d of the W-phase coil unit 21 and the stator core 30 do not interfere with each other.

That is, the second direction 1j and the fourth direction 1l of U-phase coil unit 1, Z-axis - theta ₂ degrees is an angle with respect to direction and is narrowed in the center space 5, the theta ₂ degrees of the stator core 30 There is no particular limitation as long as the angle does not contact the upper surface and the lower surface.

  In addition, the number of coil units, teeth, slots, etc. arranged in the stator core may be changed as appropriate, and it is not a three-phase coil unit composed of U-phase, V-phase, and W-phase. A two-phase coil unit in which different types of coil units are arranged may be used.

  In the fourth embodiment, the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21 are used as the coil unit for the stator, but may be used as the coil unit for the rotor.

  In addition, the stator core 30 of the fourth embodiment has a rotor disposed therein, but the rotor may be a stator for an outer rotor installed on the outside, and the U-phase coil unit 1, V The phase coil unit 11 and the W phase coil unit 21 may be used.

  Further, the flat wire 2 may be continuously changed in thickness 2t and width 2w in the length direction. When used as the stator coil unit of the fourth embodiment, it is preferable that the flat wire 2 has a wider width at the beginning of winding than at the end of winding. In this case, the first side and the third side in each coil unit have a shape in which the width 2w is narrowed in the stacking direction. In other words, the cross section of the first side 1a and the third side 1c in the direction perpendicular to the Y-axis has a trapezoidal shape. Here, as shown in FIG. 20B, the shape of the slot 32 is a trapezoidal shape whose width increases from the center toward the outer periphery, so the conductor space factor can be improved. In the case of the rotor coil unit and the stator coil unit for the outer rotor, it is preferable to use a rectangular wire whose width is narrower at the beginning of the winding than at the end of the winding.

  As described above, when the thickness and width of the rectangular wire 2 are changed in the length direction, it is preferable that the cross-sectional area is the same at an arbitrary position in the length direction.

  Further, the stator slot 32 in the fourth embodiment is formed in parallel to the central axis of the cylindrical stator core 30, but may be formed to have a predetermined angle. By doing in this way, it becomes possible to prevent coking more. In this case, in the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21, the first side and the third side are inclined with respect to the Y-axis direction. It becomes a substantially parallelogram shape.

(Embodiment 5)
The U-phase coil unit manufacturing jig of the fifth embodiment, which is an example of the coil unit manufacturing jig of the present invention, will be described below, and an example of the coil manufacturing jig of the present invention will be described simultaneously. The U-phase coil unit manufacturing jig of the fifth embodiment is a jig for manufacturing the U-phase coil unit 1 of the first embodiment.

  FIG. 21A is a perspective view of a U-phase coil unit manufacturing jig according to the fifth embodiment. FIG. 21 (b) is a diagram in which the U-phase coil unit manufactured in (a) is added by a two-dot chain line. 22 (a), 22 (b), and 22 (c) show a front view, a top view, and a right side view of the U-phase coil unit manufacturing jig shown in FIG. 21 (a). Similarly to FIG. 1, directions are represented by X, Y and Z axes.

  As shown in FIG. 22B, the U-phase coil unit manufacturing jig according to the fifth embodiment is located in the Z axis + direction and the Z axis − direction as viewed from the Y axis + direction side. A jig main body 40 having a substantially isosceles trapezoidal shape in which the sides are parallel and the side located in the Z axis + direction is smaller than the side located in the Z axis-direction is provided. . As shown in FIG. 22 (c), the jig body 40 has two sides parallel to the Z axis + direction and the Z axis − direction even when viewed from the X axis + direction side. The side located in the + direction has a substantially isosceles trapezoidal shape that is larger than the side located in the Z-axis-direction.

Further, as shown in FIG. 22 (b), the first groove 40a and the third groove 40a and the third groove are formed in the X axis-direction side surface portion and the X axis + direction side surface portion of the jig body 40 as viewed from the Y axis + direction side. A groove 40c is provided. Further, the jig body 40 has a side wall 41 provided on the X-axis-direction side of the first groove 40a to form the first groove 40a, and an X axis of the third groove 40c to form the third groove 40c. And a side wall 42 provided on the + direction side. The side wall 41 and the side wall 42 are configured to be detachable from the jig body 40. The first groove 40a is a groove for forming the first side 1a of the U-phase coil unit 1, and the third groove 40c is a groove for forming the third side 1c. The widths of the first groove 40 a and the third groove 40 c substantially coincide with the width 2 w of the flat wire 2. When the direction toward the bottom surface of the first groove 40a is the first bottom surface direction 40i and the direction toward the bottom surface of the third groove 40c is the third bottom surface direction 40k, the first bottom surface direction 40i is The _first bottom surface direction 40k is inclined in the direction of θ ₁ degree X-axis with respect to the Z-axis direction. That is, the first bottom surface direction 40i is the opposite direction to the first direction 1i of the U-phase coil unit 1, and the third bottom surface direction 40k is the opposite direction to the third direction 1k.

  Further, as shown in FIGS. 22A and 22C, the second groove 40b is formed at the end of the jig body 40 in the Y-axis − direction and the end of the Y-axis + direction when viewed from the X-axis + direction side. And the 4th groove | channel 40d is provided. The jig body 40 has a side wall 43 provided on the Y-axis side of the second groove 40b to form the second groove 40b, and a Y axis of the fourth groove 40d to form the fourth groove 40d. And a side wall 44 provided on the + direction side. The side wall 43 and the side wall 44 are configured to be detachable from the jig body 40. The second groove 40b is a groove for forming the second side 1b of the U-phase coil unit 1, and the fourth groove 40d is a groove for forming the fourth side 1d.

As described with reference to FIG. 2, the second side 1b is composed of four sides 1b ₁ , 1b ₂ , 1b ₃ , 1b ₄ . As shown in FIG. 20C, the second groove 40b has a width capable of forming these four sides, and has a width substantially four times the width 2w of the wire 2. Become. The second groove 40b corresponds to four side portions and has groove bottom portions 40b ₁ , 40b ₂ , 40b ₃ , and 40b ₄ that form steps in the width direction. These groove bottom portions 40b ₁ , 40b ₂ , 40b ₃ , 40b ₄ are arranged in the Y-axis-direction, and the direction toward the bottom surface is the same. A direction toward the bottom surface is defined as a second bottom surface direction 40j. Similarly, the fourth groove 40d has groove bottom portions 40d ₁ , 40d ₂ , 40d ₃ , 40d ₄ arranged in the Y-axis + direction, and a step is formed by these. Further, a direction toward the bottom surface of the low groove portions 40d ₁ , 40d ₂ , 40d ₃ , 40d ₄ is defined as a fourth bottom surface direction 40l.

The second bottom surface direction 40j is inclined in the θ ₂ degree Y axis − direction with respect to the Z axis + direction, and the fourth bottom surface direction 40l is inclined in the θ ₂ degree Y axis + direction with respect to the Z axis + direction. Yes. That is, the second bottom surface direction 40j is a direction opposite to the second direction 1j described in FIG. 1, and the fourth bottom surface direction 40l is a direction opposite to the fourth direction 11.

  Further, as shown in FIG. 22A, the first groove 40a, the second groove 40b, the third groove 40c, the second groove 40c are formed in a counterclockwise direction so as to form a substantially rectangular shape when viewed from the Z-axis negative direction side. Four grooves 40d are provided. Both ends of each of these grooves are open, an open portion between the first groove 40a and the second groove 40b is 40e, an open portion between the second groove 40b and the third groove 40c is 40f, and a third groove. The open part between 40c and the fourth groove 40d is marked with 40g, and the open part between the fourth groove 40d and the first groove 40a is marked with 40h.

  FIG. 23 is an exploded view of FIG. As shown in FIG. 23, the jig body 40 includes a first base material 45 and a second base material 46. The first base material 45 has a quadrangular prism shape, and is two isosceles trapezoidal surfaces having two sides parallel to each other and perpendicular to the Z axis when viewed from the Y axis + direction and Y axis − direction sides. It has. These two surfaces are isosceles trapezoidal surfaces in which the side on the Z axis + direction side is shorter than the side on the Z axis-direction side among the two sides parallel to each other. Further, the first base member 45 includes two isosceles trapezoidal surfaces having two sides parallel to each other and perpendicular to the Z axis when viewed from the X axis + direction and the X axis − direction side. These two surfaces are isosceles trapezoidal surfaces in which the side on the Z axis + direction side is longer than the side on the Z axis − direction side among the two sides parallel to each other. A second base material 46 is detachably connected to the first base material 45 on the Z-axis negative direction side.

  Here, at the end in the X axis + direction of the portion of the second base material 46 that is in contact with the first base material 45, a convex portion 46R is provided along the side surface of the first base material 45 in the X axis + direction. ing. The convex portion 46R is sandwiched between the side wall 42 and the side surface on the X axis + side of the first base material 45, and the tip portion of the convex portion 46R forms the bottom surface of the third groove 40c. Similarly, the second substrate 46 has a convex portion 46L at the end in the X-axis direction, and the tip of the convex portion 46L forms the bottom surface of the first groove 40a.

  Further, between the first base material 45 and the side wall 43, four plates 47a, 47b, 47c, and 47d are sequentially arranged in the Y-axis negative direction. These four plates and the side wall 43 each have two through holes and are positioned by two support pins 49. Also, between the first base material 45 and the side wall 44, four plates 48a, 48b, 48c, and 48d are sequentially arranged in the Y axis + direction, and are positioned by the two support pins 49.

  Further, the eight plates are fan-shaped and have a curved portion α that bulges in the Z-axis-direction side. The curved portion α forms the curvature of the second side portion 1b and the fourth side portion 1d along the outer periphery of the stator core 30 described in the fourth embodiment.

Bend α of the plate 47a corresponds to the groove bottom portion 40b _1, turn 47b, 47c, 47d bent portion α is equivalent to the groove bottom portion _{40b 2, 40b 3, 40b 4} . Similarly, the curved portions α of the plates 48a, 48b, 48c, and 48d correspond to the groove bottom portions 40d ₁ , 40d ₂ , 40d ₃ , and 40d ₄ . In addition, the Y-axis-direction side plates 47a, 47b, 47c, 47d have a shorter length in the Z-axis-direction according to the Y-axis-direction, and the Y-axis + direction-side plates 48a, 48b, 48c, 48d. The length in the Z-axis minus direction decreases along the Y-axis plus direction. Thereby, the level | step difference demonstrated in FIG.22 (c) is formed.

  Further, in the U-phase coil unit manufacturing jig according to the fifth embodiment, the depths of the first groove 40a and the third groove 40c formed by the first base material 45 and the second base material 46, and the side wall 42 and the side wall 41 are described. This is larger than the product of the number of rectangular wires 2 (9 turns × 4 coils = 36) stacked on the first side 1a and the third side 1c of the U-phase coil unit 1 and the thickness 2t. .

  Further, in the U-phase coil unit manufacturing jig according to the fifth embodiment, the depths of the second groove 40b and the fourth groove 40d formed by the first base material 45 and the second base material 46, and the side wall 43 and the side wall 44 are described. This is larger than the product of the number of stacked first to fourth coils (9 turns) of the U-phase coil unit 1 and the thickness 2t. When the number of turns varies depending on the first to fourth coils, the depth of the second groove 40b and the fourth groove 40d is larger than the product of the maximum number of turns and the thickness 2t.

  Roughly speaking, in the U-phase coil unit manufacturing jig according to the fifth embodiment, the first bottom surface direction 40i and the third bottom surface direction 40k are substantially the same direction, and the direction is the Z-axis direction. is there. On the other hand, the second bottom surface direction 40j and the fourth bottom surface direction 40l are substantially the same direction, but the direction is the Z axis + direction opposite to the Z axis-direction.

  Next, the correspondence between the present invention and the fifth embodiment will be briefly described.

  Only the plate 48a is arranged from the four types of plates 48a, 48b, 48c and 48d described in the exploded view of FIG. 23, and only the plate 47a is arranged from the plates 47a, 47b, 47c and 47d. This corresponds to an example of a jig.

  Further, according to the present invention, “the direction toward the bottom surface of each of the second groove and the fourth groove is substantially the same direction, and the direction toward the bottom surface of the first groove and the third groove, “Substantially opposite directions” means, for example, the Z-axis + direction in which the second bottom surface direction 40j and the fourth bottom surface direction 40l of the fifth embodiment are substantially the same direction, and the first bottom surface direction 40i and the third bottom surface direction 40l. This corresponds to the bottom direction 40k being the Z-axis direction which is substantially the same direction.

  In the present invention, “the width of each of the second groove and the fourth groove is such a length that the plurality of wires can be arranged in parallel in the width direction” is, for example, Embodiment 5. This corresponds to the fact that the four second grooves 40b and the fourth grooves 40d can be arranged in the width 2w direction of the flat wire 2.

(Embodiment 6)
Below, while explaining the manufacturing method of the U-phase coil unit in Embodiment 6 which is an example of the coil unit manufacturing method of this invention, the example of the coil manufacturing method of this invention is also demonstrated.

  FIG. 24 is a perspective view of a state in which a wire is wound around the U-phase coil unit manufacturing jig described in the fifth embodiment, for explaining the manufacturing method of the U-phase coil unit according to the sixth embodiment. . Here, in the U-phase coil unit manufacturing jig shown in FIG. 24, the plates 47b, 47c, 47d, 48b, 48c, and 48d described in the exploded view of FIG. 23 are removed. Only the plate 48 a is disposed between the first base material 45 and the side wall 44. Similarly, only the plate 47 a is disposed between the first base material 45 and the side wall 43. Further, the surface 2a shown in FIG.

  First, the flat wire 2 is disposed in the first groove 40a of the U-phase coil unit manufacturing jig so that the surface 2b faces the bottom surface of the first groove 40a.

Then, the rectangular wire 2, the length direction as an axis by opening 40e, while being twisted substantially 180 degrees clockwise when viewed from the extension direction, the so its surface 2b faces the groove bottom 40b ₁ Two grooves 40b are disposed.

  Next, the flat wire 2 is twisted by 180 degrees in the clockwise direction when viewed from the extending direction with the length direction as the axis at the opening 40f, and the third groove 40c so that the surface 2b faces the bottom surface. Placed in.

Then, the rectangular wire 2, the length direction as an axis by opening 40 g, while being twisted substantially 180 degrees clockwise when viewed from the extension direction, the so its surface 2b faces the groove bottom 40d ₁ Arranged in the four grooves 40d.

  With the above operation, the first turn of the first coil 6 of the U-phase coil unit 1 is formed. Further, the above operation corresponds to an example of the sowing step of the present invention.

  Next, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40h as viewed from the extension direction, and its surface 2b is already disposed in the first groove 40a. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

  Next, the flat wire 2 is twisted by 180 degrees in the clockwise direction when viewed from the extension direction with the length direction at the opening 40e, and the surface 2b is already disposed in the second groove 40b. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

  Similarly to the above, also in the 3rd groove | channel 40c and the 4th groove | channel 40d, the flat wire 2 is arrange | positioned so that the surface 2a of the flat wire 2 already arrange | positioned may be opposed. The first coil 6 is formed by performing this operation up to the ninth turn. The operation of forming the first coil 6 corresponds to an example of the coil manufacturing method of the present invention.

  Subsequently, a first turn of the second coil 7 is formed.

FIG. 25 shows a case where a second turn is manufactured by winding a rectangular wire around the U-phase coil unit manufacturing jig described in the fifth embodiment to explain the manufacturing method of the U-phase coil unit according to the sixth embodiment. FIG. Here, as shown in FIG. 25, the plate 47b and the plate 48b are attached to the U-phase coil unit manufacturing jig. Further, FIG. 26 is an enlarged sectional view of the second groove 40b, as shown in this figure, the spacer 35 is arranged between the groove bottom portion 40b ₁ and 40b _2. The spacer 35 is a plate shape which is arranged perpendicular to the groove bottom surface, and is fixed by being sandwiched between the plates 47a and 47b constituting the groove bottom portion 40b ₁ and 40b _2. Similarly, the spacer 35 is also arranged between the groove bottom portion 40d ₁ and 40d _2.

  In addition, the flat wire 2 disposed in the second groove 40b is pressed by the wire pressing jig 36 to fix the shape. The wire pressing jig 36 is more preferably used when arranging the wire in each groove because the shape of the wire can be fixed.

  As shown in FIG. 25, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40h as viewed from the extension direction, but the surface 2b has already been in the first groove 40a. It arrange | positions so that the surface 2a of the flat wire 2 arrange | positioned may be opposed.

Then, the rectangular wire 2, the length direction as an axis by opening 40e, while being twisted substantially 180 degrees clockwise when viewed from the extension direction, the so its surface 2b faces the groove bottom 40b ₂ Two grooves 40b are disposed.

  Next, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40f as viewed from the extension direction, and its surface 2b is already disposed in the third groove 40c. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Then, the rectangular wire 2, the length direction as an axis by opening 40 g, while being twisted substantially 180 degrees clockwise when viewed from the extension direction, the so its surface 2b faces the groove bottom 40d ₂ Arranged in the four grooves 40d.

  The first turn of the second coil 7 is formed by the above operation.

  Next, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40h as viewed from the extension direction, and its surface 2b is already disposed in the first groove 40a. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Next, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40e as viewed from the extension direction, and the surface 2b of the flat wire 2 is already the groove bottom 40b of the second groove 40b. ₂ is disposed so as to face the surface 2 a of the flat wire 2 disposed on the surface 2.

  Next, the flat wire 2 is twisted substantially 180 degrees clockwise with the length direction at the opening 40f as viewed from the extension direction, and its surface 2b is already disposed in the third groove 40c. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Next, the flat wire 2 is twisted substantially 180 degrees clockwise around the length direction at the opening 40g and viewed from the extension direction, but the surface 2b of the flat wire 2 is already the groove bottom 40d of the fourth groove 40d. ₂ is disposed so as to face the surface 2 a of the flat wire 2 disposed on the surface 2. Thus, when the second coil 7 is formed, the rectangular wire 2 is disposed on the groove bottom 40b ₂ in the second groove 40b and on the groove bottom 40d ₂ in the fourth groove 40d. The second coil 7 is formed by performing this operation up to 9 turns.

Further, in forming the third coil 8, the plate 47c and 48c are added, and between the groove bottom portion 40b ₂ and 40b _3, the spacer 35 is disposed between the groove bottom portion 40d ₂ and 40d _3, second The flat wire 2 is disposed on the groove bottom 40b _{3 in the} groove 40b, and on the groove bottom 40d _{3 in} the fourth groove 40d.

Further, when forming the fourth coil 9, the plate 47d and 48d are added, and between the groove bottom portion 40b ₃ and 40b _4, the spacer 35 is disposed between the groove bottom portion 40d ₃ and 40d _4, second The flat wire 2 is disposed on the groove bottom 40b _{4 in the} groove 40b, and on the groove bottom 40d _{4 in} the fourth groove 40d.

  With the above operation, the U-phase coil unit 1 shown in FIG. 1 can be manufactured. FIGS. 27A, 27B, and 27C are a front view, a top view, and a right side view of a U-phase coil unit manufacturing jig in which the manufactured U-phase coil unit is indicated by a two-dot chain line. FIG.

  Here, as shown in the exploded view of FIG. 23, since the second base material 46, the plates 47 and 48, the side walls 41 and 42, and the like can be removed from the first base material 45, each component is attached to the first base material 45. By removing from the base material 45, the manufactured U-phase coil unit 1 can be removed from the U-phase coil unit manufacturing jig.

  Next, the correspondence between the present invention and the sixth embodiment will be briefly described.

  According to the present invention, “one side wall of the second groove and / or the fourth groove is movable so that the groove width can be adjusted” means that, for example, in Embodiments 5 and 6, the plate is attached and detached. This corresponds to moving the side wall 43 and the side wall 44 to adjust the width of the second groove 40b and the fourth groove 40d.

Further, the rectangular wire 2 forming the second coil 7 is disposed on the groove bottom portion 40d ₂ with the side surface on the Y axis + side of the fourth side portion 6d as one side wall and the other side wall as the side wall 44. Thus, the use of the side surfaces of the second side portion 6b and the fourth side portion 6d as the side wall is “one or all of the side walls of the second groove and the fourth groove are one in the present invention. It corresponds to an example of “the side surfaces of the second side and the fourth side of the coil formed before”.

Further, according to the present invention, “when the next coil manufacturing step is performed after the coil manufacturing step, the width of the second side and / or the fourth side for the next coil is moved by moving the side wall. Is a step of securing the groove bottom 40b ₂ and the groove bottom 40d ₂ for the second coil 7 by adding the plates 47b and 48b after manufacturing the first coil 6 of the sixth embodiment described above, for example. This corresponds to the securing step.

According to the present invention, “the step of securing the second groove and / or the fourth groove for the next coil including the width of the spacer by moving the side wall after the coil manufacturing step” For example, by adding the spacer 35 and the plates 47b and 48b after manufacturing the first coil 6 in the sixth embodiment, the width of the spacer 35 and the groove bottom 40b ₂ and groove bottom 40d ₂ for the second coil 7 can be reduced. This corresponds to the securing step.

  Next, a modification of the sixth embodiment will be described.

  In the manufacturing method of the U-phase coil unit 1 according to the sixth embodiment, when the first coil 6 is manufactured, only the plate 47a and the plate 48a are provided, and when the second coil 7 is manufactured, the plate 47b and the plate The plate is attached every time the coil is manufactured, such as further attaching 48b. However, the plates 47a, b, c, d and the plates 47a, b, c, d may all be provided from the beginning.

In the coil unit manufacturing method of the sixth embodiment, when the second coil 7 is manufactured, the spacers are provided between the groove bottom 40b ₁ and the groove bottom 40b ₂ and between the groove bottom 40d ₁ and the groove bottom 40d _2. 35 is disposed, but the spacer 35 may not be disposed. In this case, the side surface on the Y axis − side of the second side portion 6 b of the first coil 6 is set as one side wall, and the other side wall is set as the side wall 43, to the groove bottom portion 40 _b 2 of the rectangular wire 2 forming the second coil 7. Is placed.

  In the sixth embodiment, the flat wire 2 is first arranged in the first groove 40a, and finally the manufacturing process of the U-phase coil unit 1 is completed by the arrangement in the fourth groove 40d. You may complete | finish by arrangement | positioning to the 3rd groove | channel 40c, without performing arrangement | positioning to the groove | channel 40d. As described above, when used as a stator coil unit, it is sufficient that at least the number of stacked rectangular wires 2 in the first side portion 1a and the third side portion 1c is the same.

(Embodiment 7)
The V-phase coil unit manufacturing jig of Embodiment 7 as an example of the coil unit manufacturing jig of the present invention will be described below, and an example of the coil manufacturing jig of the present invention will be described simultaneously. The V-phase coil unit manufacturing jig of the seventh embodiment is a jig for manufacturing the V-phase coil unit 11 of the second embodiment.

  FIG. 28A is a perspective view of the V-phase coil unit manufacturing jig of the seventh embodiment. FIG. 28B is a diagram in which the V-phase coil unit manufactured in the V-phase coil unit manufacturing jig shown in FIG. 29 (a), (b), and (c) are back views of the U-phase coil unit manufacturing jig shown in FIG. 28 (a) viewed from the Z-axis direction + side, and the Y-axis direction + side. The top view seen from the left side view seen from the X-axis direction-side is shown. In FIG. 29C, the V-phase coil unit 11 manufactured in the direction of the jig is drawn so as to correspond to FIG. 8D.

  FIG. 30A is a perspective view of the V-phase coil unit manufacturing jig, and FIG. 30B is an exploded view of the V-phase coil unit manufacturing jig shown in FIG.

  The V-phase coil unit manufacturing jig of the seventh embodiment has the same basic configuration as the U-phase coil unit manufacturing jig of the fifth embodiment, but the second bottom surface direction in the second groove and the fourth groove. And the fourth bottom surface direction is different from the U-phase coil unit manufacturing jig of the fifth embodiment. Therefore, this difference will be mainly described. In addition, the code | symbol which shows each part in a V-phase coil unit manufacturing jig shall add 10 to the code | symbol which shows each part of a U-phase coil unit manufacturing jig. In addition, in the V-phase coil unit manufacturing jig and the U-phase coil unit manufacturing jig, the description of the reference numerals of the V-phase coil unit manufacturing jig is omitted for parts that are basically common.

In the V-phase coil unit manufacturing jig according to the seventh embodiment of the present invention, the second bottom surface direction 50j is θ ₃ degrees from the Y-axis direction relative to the Z-axis direction, and the fourth bottom surface direction 50l is , With respect to the Z axis minus direction, θ ₃ degrees from the Y axis plus direction. As described in the second embodiment, θ ₃ can take a value larger than 0 degree and smaller than 90 degrees.

  Next, the correspondence between the present invention and the seventh embodiment will be briefly described.

  According to the present invention, “the direction toward the bottom surface of each of the second groove and the fourth groove is greater than 90 degrees and smaller than 180 degrees with respect to the bottom surface direction of the first groove and the third groove. For example, “is the second bottom surface direction 50j and the fourth bottom surface direction 50l in the seventh embodiment are in the Z-axis direction, which is substantially the same direction as the first bottom surface direction 50i and the third bottom surface direction 50k. This corresponds to a direction that is larger than 90 degrees (Y axis + direction or Y axis-direction) and smaller than 180 degrees (Z axis-direction) with respect to the Z axis + direction.

(Embodiment 8)
Below, while explaining the manufacturing method of the V phase coil unit in Embodiment 8 which is an example of the coil unit manufacturing method of this invention, the example of the coil manufacturing method of this invention is also demonstrated. Since the basic operation of the manufacturing method of the V-phase coil unit in the eighth embodiment is the same as that of the U-phase coil unit in the sixth embodiment, only the manufacturing process of the first coil 16 will be described below. I do.

  FIG. 31 is a perspective view of a state in which a wire is wound around the V-phase coil unit manufacturing jig described in the seventh embodiment for explaining the method for manufacturing the V-phase coil unit according to the eighth embodiment. .

  First, the flat wire 2 is disposed in the first groove 50a of the V-phase coil unit manufacturing jig so that the surface 2b faces the bottom surface of the first groove 50a (see FIGS. 29 and 31).

Then, the rectangular wire 2, the length direction as an axis by opening 50e, while being twisted clockwise when viewed from the extension direction, the second groove 50b so that the surface 2b is opposed to the groove bottom portion 50b ₁ Be placed.

  Next, the flat wire 2 is arranged in the third groove 50c so that the surface 2b faces the bottom surface while being twisted clockwise as viewed from the extension direction with the length direction at the opening portion 50f. .

Then, the rectangular wire 2, the length direction as an axis by opening 50 g, while being twisted clockwise when viewed from the extension direction, the fourth groove 50d so that the surface 2b is opposed to the groove bottom 50d ₁ Be placed.

  With the above operation, the first turn of the first coil 16 of the V-phase coil unit 11 is formed.

  Hereinafter, the V-phase coil unit 11 is manufactured by forming the second coil 17, the third coil 18, and the fourth coil 19 in the same manner as the manufacturing method of the U-phase coil unit described in the sixth embodiment. .

  Note that the angle when clockwise twisted in the eighth embodiment is greater than 90 degrees and smaller than 180 degrees.

  32 (a), (b), and (c), a back view, a top view, and a left side view of a V-phase coil unit manufacturing jig in which the manufactured V-phase coil unit is indicated by a two-dot chain line. Indicates.

(Embodiment 9)
The W-phase coil unit manufacturing jig of Embodiment 9 as an example of the coil unit manufacturing jig of the present invention will be described below, and an example of the coil manufacturing jig of the present invention will be described at the same time. The W-phase coil unit manufacturing jig of the ninth embodiment is a jig for manufacturing the W-phase coil unit 21 of the third embodiment.

  FIG. 33A is a perspective view of a W-phase coil unit manufacturing jig according to the ninth embodiment of the present invention. FIG. 33B is a diagram in which the W-phase coil unit manufactured in FIG. 34 (a) is a back view of the W-phase coil unit manufacturing jig shown in FIG. 33 (a) as seen from the Z axis + direction, and FIG. 34 (b) is a top view as seen from the Y axis + direction. It is a figure and (c) is the left view seen from the X-axis negative direction.

  As shown in FIGS. 33 and 34B, the W-phase coil unit manufacturing jig according to the ninth embodiment has a quadrangular prism shape in which the surface shapes on the Y axis + side and the Y axis − side are substantially trapezoidal. The jig main body 60 is provided. This trapezoidal shape is a trapezoidal shape in which two sides in the Z-axis direction are parallel.

  34A, the first groove 60a and the first groove 60a are formed in the X-axis-side side surface portion and the X-axis + direction side surface portion of the jig body 60, as shown in FIG. Three grooves 60c are provided. The jig body 60 has a side wall 61 provided on the X-axis direction side of the first groove 60a to form the first groove 60a, and an X of the third groove 60c to form the third groove 60c. And a side wall 62 provided on the axis + direction side. The side wall 61 and the side wall 62 are configured to be detachable from the jig body 60.

The first groove 60a is a groove for forming the first side portion 21a of the W-phase coil unit 21, and the third groove 60c is a groove for forming the third side portion 21c. The widths of the first groove 60 a and the third groove 60 c substantially coincide with the width 2 w of the flat wire 2. When the direction toward the bottom surface of the first groove 60a is the first bottom surface direction 60i and the direction toward the bottom surface of the third groove 60c is the third bottom surface direction 60k, the first bottom surface direction 60i is The _first bottom surface direction 60k is inclined in the θ ₁ degree X axis + direction with respect to the Z axis-direction. That is, the direction is opposite to the first direction 21 i of the W-phase coil unit 1, and the third bottom surface direction 60 k is opposite to the third direction 21 k.

  FIG. 35 (a) is a perspective view of the W-phase coil unit manufacturing jig of the ninth embodiment, and FIG. 35 (b) is an exploded view thereof. As shown in FIG. 35B, the jig body 60 includes a first base material 65 and a second base material 66. The first base material 65 has a quadrangular prism shape, and has two isosceles trapezoidal surfaces having two parallel sides arranged perpendicular to the Z axis when viewed from the Y axis + direction side and the Y axis − direction side. I have. These two surfaces are isosceles trapezoidal surfaces of which two sides parallel to each other are shorter on the Z-axis + side than on the Z-axis-side.

  The second substrate 66 has the same shape, but the end in the X axis + direction of the portion in contact with the first substrate 65 protrudes along the side surface of the first substrate 65 in the X axis + direction. 66R is provided. The convex portion 66R is sandwiched between the side wall 61 and the side surface on the X axis + side of the first base member 65, and the tip of the convex portion 66R forms the bottom surface of the third groove 60c. Similarly, the second base material 66 has a convex portion 66L at the end in the X-axis direction, and the tip of the convex portion 66L forms the bottom surface of the first groove 60a.

36 (a), (b), (c), and (d) are views of the W-phase coil unit manufacturing jig of the ninth embodiment as seen from the Y axis + direction. As shown in FIG. 36 (a), a fourth groove forming first member 67a is arranged on the Z axis + side, and a fourth groove forming second member 68 is arranged on the Z axis-side. , the fourth groove first portion 60d ₁ is formed. Shown, the shaded portion is along the substantially X-axis is a fourth groove first portion 60d _1, shows a part of the fourth groove 60d that flat wire 2 is arranged. The fourth groove forming second member has a curved portion β on the fourth groove first portion 60d ₁ side. Specifically, as will be described later, by the fourth groove first portion 60d _1, the fourth side portion 26d of the first coil 26 shown in FIG. 15 is formed. Also, the curved portion β forms the curvature of the second side portion 21b and the fourth side portion 21d along the outer peripheral portion of the stator core 30 described in the fourth embodiment.

As shown in FIG. 36B, the jig body 60 has a similar shape to the fourth groove forming first member 67a shown in FIG. A groove forming first member 67b is arranged. The fourth groove forming first member 67b is reduced in the Z-axis − direction and the X-axis + − direction compared to 67a. Further, a spacer 69 a is disposed between the fourth groove forming first member 67 b and the fourth groove forming second member 68. The spacer 69a includes a fourth groove second parts of which are arranged in a fourth Z-axis positive side of the groove first portion 60d _1, the Z-axis positive side and the fourth groove forming the first member 67b of the spacer 69a and the side wall 60d ₂ is formed. This fourth groove part 2 60d _2, the fourth side portion 27d of the second coil 27 shown in FIG. 15 is formed. The spacer 69a also has a curved portion β on the Z axis + side, like the fourth groove forming second member 68.

Similarly to the above, as shown in FIG. 36 (c), the jig main body 60 is formed with a fourth groove formation similar to the fourth groove formation first member 67b shown in FIG. 36 (b). A first member 67c is arranged. A spacer 69b is further disposed between the fourth groove forming first member 67c and the spacer 69a, and the fourth groove forming first side 67c and the fourth groove forming first member 67c are used as side walls. part 3 60d ₃ are formed. This fourth groove Part 3 60d _3, the fourth side portion 28d of the third coil 28 shown in FIG. 15 is formed.

As shown in FIG. 36 (d), the jig body 60 has a fourth groove forming first member 67d, which is similar to the fourth groove forming first member 67c shown in (c). Has been placed. A spacer 69c is further arranged between the fourth groove forming first member 67d and the spacer 69b, and the fourth groove forming first side 67d and the fourth groove forming first member 67d are used as side walls. part 4 60d ₄ are formed. This fourth groove Part 4 60d _4, the fourth side portion 29d of the fourth coil 29 shown in FIG. 15 is formed. Both the spacers 69b and 69c have a curved portion β on the X axis + side.

  FIG. 35 (b) shows an exploded view of the jig body 60 in the state shown in FIG. 36 (d).

  Further, the spacer fixing jig 70 installed on the Y axis + side of the fourth groove forming second member 68 shown in FIG. 35B is omitted in FIG. 36 for explanation. The spacer fixing jig 70 is fixed so as to be movable in the Z-axis direction.

FIGS. 37A and 37B are views of the W-phase coil unit manufacturing jig for explaining the spacer fixing jig 70 as seen from the Y axis + direction. Figure 37 (a) is the same as the state of FIG. 36 (a), the only the fourth groove first portion 60d ₁ is formed. At this time, the spacer fixing jig 70 is retracted in the Z-axis-direction.

Figure 37 (b) is the same as the state of FIG. 36 (b), the fourth groove first portion 60d ₁ and the fourth groove second portion 60d ₂ are formed. At this time, the spacer fixing jig 70 is fixed by moving in the Z-axis + direction and pressing the spacer 69a from the Y-axis + direction. Similarly, the spacer fixing jig 70 is movable in the Z axis + direction so as to hold the spacers 69b and 69c.

  As shown in FIG. 35 (b), the second groove forming first member 71b and the second groove forming side are arranged on the Y axis direction minus side as in the Y axis direction plus side (fourth groove side) of the jig body 60. A groove forming second member 72, spacers 73a, 73b, 73c, and a spacer fixing jig 74 are provided. Similarly to the fourth groove side, the W-phase coil manufacturing jig includes four types of second groove forming first members 71a, 71b, 71c, 71d that can be attached to and detached from the jig body 60.

  As shown in FIG. 34C, the second bottom surface direction 60j, which is the bottom surface direction of the second groove 60b, is the Y axis + direction, and the fourth bottom surface direction 60l, which is the bottom surface direction of the fourth groove 60d, is Y. Axis-direction.

  As shown in FIG. 34A, both ends of each of the first groove 60a, the second groove 60b, the third groove 60c, and the fourth groove 60d are open, and the first groove 60a and the second groove 60d are opened. The open portion between the grooves 60b is 60e, the open portion between the second groove 60b and the third groove 60c is 60f, the open portion between the third groove 60c and the fourth groove 60d is 60g, and the fourth groove An open portion between 60d and the first groove 60a is 60h.

  In the W-phase coil unit manufacturing jig according to the ninth embodiment, the depths of the first groove 60a and the third groove 60c are stacked on the first side 21a and the third side 21c of the W-phase coil unit 21. It is larger than the product of the number of rectangular wires 2 (9 turns × 4 coils = 36) and the thickness 2t.

  Further, in the W-phase coil unit manufacturing jig according to the ninth embodiment, the depth of the second groove 60b and the fourth groove 60d is the number of stacked first to fourth coils of the U-phase coil unit 1 (9 turns). It is larger than the product of the thickness 2t. When the number of turns varies depending on the first to fourth coils, the depth of the second groove 60b and the fourth groove 60d is larger than the product of the maximum number of turns and the thickness 2t.

  Next, the correspondence between the present invention and the ninth embodiment will be briefly described.

  The fourth groove forming first member 67a and the fourth groove forming second member 68, and the second groove forming first member 71a and the second groove forming second member 72 described in FIG. The state arrange | positioned in corresponds to an example of the coil manufacturing jig | tool of this invention.

  Further, according to the present invention, “the direction toward the bottom surface of each of the second groove and the fourth groove is opposite to each other, and the direction toward the bottom surface of the first groove and the third groove, The “substantially vertical direction” means, for example, that the second bottom surface direction 60j of the ninth embodiment is substantially the Y axis + direction, the fourth bottom surface direction 60l is the substantially Y axis − direction, and the first bottom surface direction. The direction 60i and the third bottom surface direction 60k correspond to the Z axis-direction that is substantially the same direction.

  In the present invention, “the width of each of the second groove and the fourth groove is such a length that the plurality of wires can be arranged in parallel in the width direction” is, for example, Embodiment 9. This corresponds to the fact that four second grooves 60 b and four fourth grooves 60 d can be arranged in the width 2 w direction of the flat wire 2.

(Embodiment 10)
Below, while explaining the manufacturing method of the W phase coil unit in Embodiment 10 which is an example of the coil unit manufacturing method of this invention, the example of the coil manufacturing method of this invention is also demonstrated.

  FIG. 38 is a perspective view of a state in which a wire is wound around the W-phase coil unit manufacturing jig described in the ninth embodiment for describing the method for manufacturing the W-phase coil unit according to the tenth embodiment. . Here, in the W-phase coil unit manufacturing jig shown in FIG. 38, the fourth groove forming first member 67a and the fourth groove forming second member 68 described in FIG. A first member 71a and a second groove forming second member 72 are attached. The spacer fixing jigs 70 and 74 are not attached to the jig main body 60 in FIG. 38, but may be attached. However, when the spacer fixing jigs 70 and 74 are attached, they are retracted and attached in the Z-axis-direction as shown in FIG.

First, flat wire 2, the surface 2b are disposed in the fourth groove 60d of the V-phase coil unit manufacturing jig so as to face the fourth bottom of the groove first portion 60d _1. The portion disposed in the fourth groove 60d corresponds to the starting portion 23 shown in FIG. 13 (see FIGS. 34, 37, and 38).

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60h so that the surface 2b faces the bottom surface of the first groove 60a. In the first groove 60a.

Then, the rectangular wire 2, the length direction as an axis by opening 60e, while being twisted substantially 90 degrees clockwise when viewed from the extension direction, the surface 2b second groove first portion bottom surface of 60b ₁ It arrange | positions in the 2nd groove | channel 60b so that it may oppose.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise with respect to the length direction at the opening 60f as viewed in the extension direction, and the third groove 60c so that the surface 2b faces the bottom surface. Placed in.

Then, the rectangular wire 2, an axis length direction at the opening portion 60 g, while being twisted substantially 90 degrees clockwise when viewed from the extension direction, the surface 2b fourth groove first portion bottom surface of 60d ₁ It is arranged in the fourth groove 60d so as to face.

  With the above operation, the first turn of the first coil 26 of the W-phase coil unit 21 is formed.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction as an axis at the opening 60e, and its surface 2b is already disposed in the first groove 60a. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60e, and the surface 2b is already disposed in the second groove 60b. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

  Similarly to the above, also in the 3rd groove | channel 60c and the 4th groove | channel 60d, the flat wire 2 is arrange | positioned so as to oppose the surface 2a of the flat wire 2 already arrange | positioned. The first coil 26 is formed by performing this operation up to the ninth turn.

  Subsequently, a first turn of the second coil 27 is formed.

Prior to manufacturing the second coil 27, the fourth groove forming first member 67a is replaced with the fourth groove forming first member 67b, and the spacer 69a is disposed. Then, the spacer fixing jig 70 is moved in the Z axis + direction so as to fix the spacer 69a. This state corresponds to FIG. As shown in FIG. 37 (b), the spacer fixture 70 is arranged so as not to cover the fourth groove part 2 60d _2. Similarly, the second groove forming first member 71a is replaced with the second groove forming first member 71b, and the spacer 73a is disposed. Then, the spacer fixing jig 74 is moved in the Z axis + direction so as to fix the spacer 73a.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60h, and the surface 2b is already disposed in the first groove 60a. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Then, the rectangular wire 2, an axis length direction at the opening portion 60e, while being twisted substantially 90 degrees clockwise when viewed from the extension direction, a bottom surface that face 2b of the second groove part 2 60b ₂ It arrange | positions so that it may oppose.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60f, and the surface 2b is already disposed in the third groove 60c. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Then, the rectangular wire 2, an axis length direction at the opening portion 60 g, while being twisted substantially 90 degrees clockwise when viewed from the extension direction, the bottom surface thereof faces 2b of the fourth groove part 2 60d ₂ It arrange | positions so that it may oppose.

  With the above operation, the first turn of the second coil 27 is formed. FIG. 39 is a diagram showing a process of forming the second coil 27.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60h, and the surface 2b is already disposed in the first groove 60a. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Next, the flat wire 2 is twisted substantially 90 degrees in the clockwise direction when viewed from the extending direction with the opening 60e as the axis in the length direction, and the surface 2b is already in the second groove second portion 60b _2. It arrange | positions so that the surface 2a of the flat wire 2 arrange | positioned above may be opposed.

  Next, the flat wire 2 is twisted substantially 90 degrees clockwise as viewed from the extension direction with the length direction at the opening 60f, and the surface 2b is already disposed in the third groove 60c. It arrange | positions so that the surface 2a of the flat wire 2 may be opposed.

Next, the flat wire 2 is twisted substantially 90 degrees clockwise with the length direction as the axis at the opening 60g and viewed from the extension direction, but the surface 2b has already been in the fourth groove second portion 60d _2. It arrange | positions so that the surface 2a of the flat wire 2 arrange | positioned above may be opposed. Thus, in forming the second coil 27, the second upper groove 60b in the second groove second portion 60b _2, the fourth groove 60d, the flat wire on the fourth groove part 2 60d ₂ 2 Is placed. The second coil 27 is formed by performing this operation up to 9 turns.

Further, when the third coil 28 is formed, a fourth groove forming first member 67c is attached instead of the fourth groove forming first member 67b as shown in FIG. A spacer 69b is disposed between the member 67c and the spacer 69a. Then, the spacer fixing jig 70 is moved in the Z axis + direction, and the spacer 69b is fixed. Similarly, on the second groove side, a fourth groove forming first member 71c is attached instead of the second groove forming first member 71b, and a spacer 73b is provided between the fourth groove forming first member 71c and the spacer 73a. Be placed. Then, the spacer fixing jig 74 is moved in the Z axis + direction, and the spacer 73b is fixed. Thereafter, the flat wire 2 is arranged in the second groove third portion 60b ₃ in the second groove 60b, and in the fourth groove third portion 60d ₃ in the fourth groove 60d. A coil 28 is formed.

Further, when the fourth coil 29 is formed, a fourth groove forming first member 67d is attached instead of the fourth groove forming first member 67c as shown in FIG. A spacer 69c is disposed between the member 67d and the spacer 69b. Then, the spacer fixing jig 70 is moved in the Z axis + direction, and the spacer 69c is fixed. The same operation is performed on the second groove side. Thereafter, the flat wire 2 is arranged in the second groove fourth portion 60b ₄ in the second groove 60b, and in the fourth groove fourth portion 60d ₄ in the fourth groove 60d. A coil 29 is formed.

  With the above operation, the W-phase coil unit 21 shown in FIG. 13 can be manufactured. 40 (a), (b), and (c) are a back view, a top view, and a left side view of a W-phase coil unit manufacturing jig in which the manufactured W-phase coil unit is indicated by a two-dot chain line. Show.

  Here, as shown in the exploded view of FIG. 35, the manufactured W-phase coil unit 21 can be removed from the W-phase coil unit manufacturing jig by removing each component from the first base 65. . For example, the second groove forming first member 67d, the fourth groove forming first member 71d, the spacer fixing jigs 70 and 74, the spacers 69a, b, and c, and the spacers 73a, b, and c are replaced with the first base material 65 and By removing from the second base material 66, the manufactured W-phase coil unit 21 can be removed.

  Further, as shown in FIG. 39, in the W-phase coil unit manufacturing jig according to the ninth embodiment, the length (γ) obtained by adding the width 2W of the flat wire 2 and the width in the Z-axis direction of the spacer, and the flat wire 2 The width of the rectangular wire 2, the thickness, and the width of the spacer are configured so that the length (ε) obtained by multiplying the thickness 2t by 9 which is the number of turns of each coil is substantially the same. However, for example, when the width of the flat wire 2 is increased with respect to the thickness, it may not be necessary to reduce the width of the spacer or to provide the spacer itself. It is possible to make changes.

  Next, the correspondence between the present invention and the ninth and tenth embodiments will be briefly described.

  In the present invention, “the one side wall of the second groove and / or the fourth groove is movable so that the groove width can be adjusted” means that, for example, in Embodiments 9 and 10, there are four types of The widths of the second groove 60b and the fourth groove 60d can be adjusted by replacing the second groove forming first members 71a, 71b, 71c, 71d and the four types of fourth groove forming first members 67a, 67b, 67c, 67d. It corresponds to that.

According to the present invention, “the step of securing the second groove and / or the fourth groove for the next coil including the width of the spacer by moving the side wall after the coil manufacturing step” For example, spacers 69a and 73a are added after the production of the first coil 26 in the tenth embodiment, and the width of the spacer is changed by changing to the second groove forming first member 67b and the fourth groove forming first member 71b. This corresponds to the step of securing the second groove second portion 60b ₂ and the fourth groove second portion 60d ₂ for the second coil 27.

  Next, a modification of the above-described embodiment will be described.

  In the coil unit manufacturing method according to the sixth, eighth, and tenth embodiments, the flat wire 2 is arranged in each groove while being twisted, but may be arranged in each groove after being twisted in each open portion.

  Further, by incorporating the U-phase coil unit 1, the V-phase coil unit 11, and the W-phase coil unit 21 manufactured in the sixth, eighth, and tenth embodiments into the stator core 30, the stator shown in the fourth embodiment. However, the stator can also be created by attaching the manufacturing jigs of Embodiments 5, 7, and 9 to the stator core 30 and directly rolling the flat wire 2.

  Such a case will be described by taking as an example a case where the U-phase coil manufacturing jig is attached to the stator core. 41 (a) and 41 (b) are a plan view and a side view in which a U-phase coil manufacturing jig is attached to a stator core. As shown in the drawing, in the U-phase coil manufacturing jig of this modification, the portions where the second groove 40b and the fourth groove 40d of the jig body 40 shown in FIG. 22 are formed are arranged on the upper and lower surfaces of the stator core 30. It has become the composition. The first groove 40a of the jig body 40 corresponds to the slot 32u of the stator core 30, and the fourth groove 40d corresponds to the slot 32u ′. In the figure, the U-phase coil 1 manufactured by the U-phase coil manufacturing jig of this modification is indicated by a dotted line. The same applies to the V-phase coil manufacturing jig and the W-phase coil manufacturing jig.

  Further, each coil may be used for a transformer and a linear motor, and it is possible to improve the conductor space factor and cope with the shape of the mounting space of the transformer.

Further, the first direction and the third direction in the coil and the coil unit both have an angle of θ ₁ degree with respect to the Z axis + direction, but are determined according to the shape of the stator core 30. For example, when used as a transformer, the angle with respect to the Z-axis + direction may be different.

  The second side and the fourth side in the coil and coil unit are substantially curved along the outer periphery of the stator core 30, but this curve is not provided when used as a transformer. Also good.

  In addition, although the wire rod of this invention is corresponded to the flat wire 2 mentioned above, it is not limited by the shape of a cross section, A round wire, a square wire, etc. may be sufficient.

  Moreover, although the coil unit demonstrated in said each embodiment is provided with four coils and each coil has 1st-9th turn, there is no limitation in these numbers, You may change suitably.

(Embodiment 11)
Below, while explaining the structure of the U-phase coil unit in Embodiment 11 which is an example of the coil unit of this invention, the example of the coil of this invention is also demonstrated simultaneously.

  FIG. 50 is a perspective view of a U-phase coil unit according to Embodiment 11 of the present invention. 51A to 51D are a front view, a top view, a right side view, and a left side view of the U-phase coil unit shown in FIG. 50, respectively.

  The U-phase coil unit 201 according to the eleventh embodiment has the same basic configuration as the U-phase coil unit 1 according to the first embodiment described above. However, the rectangular wire 2 on the second side and the fourth side is the same. The stacking direction is different from that of the first embodiment. Further, the number of coils constituting the U-phase coil unit, the number of turns of each coil, and the arrangement of the second side portion and the fourth side portion between the coils are different. Therefore, this difference will be mainly described.

  In addition, the code | symbol which shows each part in the U-phase coil unit 201 of this Embodiment 11 shall add 200 to the code | symbol which shows each part of the U-phase coil unit 1, and has shown only the principal part. The first direction 201i and the third direction 201k indicate the same direction as the first direction 1i and the third direction 1k of the first embodiment.

  As shown in FIGS. 50 and 51, in the U-phase coil unit 201 of the eleventh embodiment, the second direction 201j is substantially the Y axis-direction, and the fourth direction 201l is substantially Y. Axis + direction.

  That is, the U-phase coil unit 201 of the eleventh embodiment is formed so that the second direction 201j and the fourth direction 201l are substantially opposite directions, and the W-phase coil unit 21 of the third embodiment is modified. Is equivalent to

  Therefore, hereinafter, the U-phase coil unit 201 of the eleventh embodiment will be described in comparison with the W-phase coil unit 21 of the third embodiment.

  As shown in FIG. 50 and FIG. 51 (b), the U-phase coil unit 201 of the eleventh embodiment is similar to the third embodiment in that the first and second sides 201 a and 201 c are opposed to each other. , The second side part 201b and the fourth side part 201d are opposed to each other.

  However, the U-phase coil unit 201 of the eleventh embodiment differs from the third embodiment in that the first coil 206, the second coil 207, and the third coil 208 are divided from the firing start portion 203 to the firing end portion 204. It consists of two coils. The number of turns of these three coils is 12. That is, the total number of turns of the W-phase coil unit 21 of the third embodiment and the U-phase coil unit 201 of the eleventh embodiment is both 36 times.

Therefore, the fourth side portion 201d of the U-phase coil unit 201 of the eleventh embodiment includes three side portions 201d ₁ , 201d ₂ , and 201d ₃ as shown in FIG. The second side portion 201b is also composed of _three side portions 201b ₁ , 201b ₂ , 201b ₃ .

FIG. 52 is a perspective view of the first coil 206. As shown, the first coil 206, a second side portion 206b has a fourth side portion 206d, corresponding to each of the side portions 201b ₁ and the side portion 201d ₁ (see FIG. 50 (b)) is doing. The first coil 206 has a first side part 206a and a third side part 206c, and constitutes a part of the side part 201a and the side part 201c, respectively. The first direction 206i, the second direction 206j, the third direction 206k, and the fourth direction 206l of the first coil 206 are respectively the first direction 201i, the second direction 201j, and the third direction of the U-phase coil unit 201. 201k and substantially the same as the fourth direction 201l.

  Further, as shown in FIGS. 50 (c) and 50 (d), when viewed from the side, the U-phase coil unit 201 of the eleventh embodiment has positions of the second side 201b and the fourth side 201d, The first side portion 201a and the third side portion 201c are formed so as to be disposed in the vicinity of the extension line in the Y-axis direction of the Z-axis-direction end 201u in the width direction. The Y-axis direction extension line is indicated by a one-dot chain line in FIGS. 54 (c) and 54 (d).

Furthermore, in the W-phase coil unit 21 of the third embodiment, as shown in FIG. 14B, a gap 100 is formed between the side portions 21d ₁ , 21d ₂ , 21d ₃ , 21d _4. In the U-phase coil unit 201 of the tenth embodiment, substantially no gap is formed between the side portions 201d ₁ , 201d ₂ , 201d ₃ . Similarly, no gap is formed between the side portions 201b ₁ , 201b ₂ , 201b ₃ .

  According to the present invention, “the coils of the plurality of coils are substantially opposite to each other in the stacking directions of the second side and the fourth side, and the one set of stacking directions. For example, in Embodiment 11, the second direction 206j and the fourth direction 206l of the first coil 206 are substantially opposite directions, and the first direction 206i and the third direction This corresponds to the direction perpendicular to the Z axis + direction which is substantially the same direction as the direction 206k.

  In addition, for example, in FIG. 52, the side surface of the present invention corresponds to the surface S formed in the Z axis − direction of the second side portion 206 b or the surface formed in the Z axis + direction.

Further, in the present embodiment, “the side surface of the second side is adjacent between the continuously connected coils” means, for example, the side part 201b ₁ and the side part 201b in the eleventh embodiment. ₂ and the side surfaces of the side portion 201b ₃ are adjacent to each other.

In the present invention, “the side surface of the fourth side is adjacent between the continuously connected coils” means, for example, in the eleventh embodiment, the side portion 201d ₁ and the side portion 201d. _2, and side surfaces of the side portions 201d ₃ corresponds to be adjacent.

  Further, in the present invention, “the second side and the fourth side of each of the plurality of coils are arranged from one surface of the first side of the coil unit” means, for example, this embodiment In the form 11, the positions of the second side portion 201b and the fourth side portion 201d are arranged in the vicinity of the Y-axis direction extension line of the Z-direction end 201u in the width direction of the first side portion 201a and the third side portion 201c. This is equivalent to being formed.

(Embodiment 12)
Hereinafter, the structure of the V-phase coil unit according to Embodiment 12, which is an example of the coil unit of the present invention, will be described, and an example of the coil of the present invention will be described at the same time.

  FIG. 53 is a perspective view of a V-phase coil unit according to the twelfth embodiment of the present invention. 54A to 54D show a front view, a top view, a right side view, and a left side view of the V-phase coil unit shown in FIG. 53, respectively.

  The V-phase coil unit 301 in the twelfth embodiment has the same basic configuration as the U-phase coil unit 201 in the eleventh embodiment, but the positions of the second side and the fourth side are the first side. Different from the U-phase coil unit 201 of the eleventh embodiment on the basis of the part and the third side part. Therefore, this difference will be mainly described. In addition, the code | symbol which shows each part in the V-phase coil unit 301 of this Embodiment 12 shall add 100 to the code | symbol which shows each part of the U-phase coil unit 201, and has shown only the principal part. The first direction 301i and the third direction 301k indicate the same direction as the first direction 201i and the third direction 201k of the eleventh embodiment. Further, as shown in FIGS. 53 and 54, in the V-phase coil unit 301 of the twelfth embodiment, the second direction 301j is substantially the Y axis-direction, and the fourth direction 301l is substantially The upper Y-axis + direction.

As shown in FIGS. 53 and 54, the V-phase coil unit of the twelfth embodiment is similar to the eleventh embodiment in the first side 301a, the second side 301b, and the third side 301c. , And a fourth side portion 301d, which is composed of three coils of a first coil 306, a second coil 307, and a third coil 308 from the winding start portion 303 to the winding end portion 304. Further, the fourth side portion 301d of the V-phase coil unit 301 of the twelfth embodiment is composed of _three side portions 301d ₁ , 301d ₂ and 301d ₃ as shown in FIG. 54 (b). The second side portion 301b is also composed of _three side portions 301b ₁ , 301b ₂ , and 301b ₃ .

FIG. 55 is a perspective view of the first coil 306. As shown, the first coil 306 has a second side portion 306b and the fourth side portion 306d, corresponding to each of the side portions 301b ₁ and the side portion 301d ₁ (see FIG. 54 (b)) is doing. The first coil 306 has a first side 306a and a third side 306c, and constitutes a part of the side 301a and the side 301c, respectively.

  As shown in FIGS. 54 (c) and 54 (d), when viewed from the side, the V-phase coil unit 301 of the twelfth embodiment has a center position 301v in the width direction of the first side 301a and the third side 301b. The second side portion 301b and the fourth side portion 301d are formed in the vicinity of the extension line in the Y-axis direction. The Y-axis direction extension line is indicated by a one-dot chain line in FIGS. 54 (c) and 54 (d).

  In the present invention, “the second side and the fourth side of each of the plurality of coils are arranged from the coil at the center of the first side of the coil unit” means, for example, In the twelfth embodiment, when viewed from the side, the second side portion 301b and the fourth side portion 301d are located in the vicinity of the Y-axis direction extension line at the center position 301v in the width direction of the first side portion 301a and the third side portion 301b. Is equivalent to being formed.

(Embodiment 13)
Hereinafter, the structure of the W-phase coil unit according to Embodiment 13, which is an example of the coil unit of the present invention, will be described, and an example of the coil of the present invention will also be described.

  FIG. 56 is a perspective view of a W-phase coil unit according to the thirteenth embodiment of the present invention. 57A to 57D respectively show a front view, a top view, a right side view, and a left side view of the V-phase coil unit shown in FIG.

  W-phase coil unit 401 in the thirteenth embodiment has the same basic configuration as U-phase coil unit 201 in the eleventh embodiment, but the positions of the second and fourth sides are the first side. Different from the U-phase coil unit 201 of the thirteenth embodiment on the basis of the part and the third side part. Therefore, this difference will be mainly described. In addition, the code | symbol which shows each part in the W-phase coil unit 401 of this Embodiment 12 shall add 200 to the code | symbol which shows each part of the U-phase coil unit 201, and has shown only the principal part. The first direction 401i and the third direction 401k indicate the same direction as the first direction 201i and the third direction 201k of the eleventh embodiment. As shown in FIGS. 56 and 57, in the W-phase coil unit 401 of the thirteenth embodiment, the second direction 401j is substantially the Y-axis-direction, and the fourth direction 401l is substantially The upper Y-axis + direction.

As shown in FIGS. 56 and 57, the W-phase coil unit of the thirteenth embodiment is similar to the eleventh embodiment in the first side 401a, the second side 401b, and the third side 401c. , And a fourth side portion 401 d, which is composed of a first coil 406, a second coil 407, and a third coil 408 from the winding start portion 403 to the winding end portion 404. Further, the fourth side portion 401d of the V-phase coil unit 401 of the thirteenth embodiment is composed of _three side portions 401d ₁ , 401d ₂ , 401d ₃ as shown in FIG. 57 (b). The second side portion 401b is also composed of _three side portions 401b ₁ , 401b ₂ , 401b ₃ .

FIG. 58 is a perspective view of the first coil 406. As shown, the first coil 406 has a second side portion 406b and the fourth side portion 406d, corresponding to each of the side portions 401b ₁ and the side portion 401d ₁ (see FIG. 57 (b)) is doing. The first coil 406 has a first side 406a and a third side 406c, and constitutes a part of the side 401a and the side 401c, respectively.

  As shown in FIGS. 57 (c) and 57 (d), when viewed from the side, the W-phase coil unit 401 of the thirteenth embodiment has positions of the second side 401b and the fourth side 401d. The first side portion 401a and the third side portion 401c are formed so as to be disposed in the vicinity of the Z axis in the width direction + the end 401w in the Y axis direction. The Y-axis direction extension line is indicated by a one-dot chain line in FIGS. 57 (c) and 57 (d).

  In the present invention, “the second side and the fourth side of each of the plurality of coils are arranged from the other surface of the first side of the coil unit” means, for example, this embodiment In the form 13, the positions of the second side 401b and the fourth side 401d are arranged in the vicinity of the Z-axis in the width direction of the first side 401a and the third side 401c + the Y-axis direction extension line of the direction end 401w. This is equivalent to being formed.

(Embodiment 14)
The stator according to the fourteenth embodiment of the present invention using the U-phase coil unit 201, the V-phase coil unit 301, and the W-phase coil unit 401 will be described below.

  FIG. 59 (a) is a perspective view of the stator according to the fourteenth embodiment. FIGS. 59 (b) and 59 (c) are a plan view and a side view of the stator shown in FIG. 59 (a). As shown in FIG. 59, the stator according to the fourteenth embodiment includes eight U-phase coil units 201, V-phase coil units 301, and W-phase coil units 401, and stator core 30.

  The stator of the fourteenth embodiment has the same basic configuration as the stator of the fourth embodiment, but the inserted coil unit is different. This difference will be mainly described. In the fourteenth embodiment, the stator core 30 used is the same as the stator core of the fourth embodiment described with reference to FIG.

  In the stator of the fourteenth embodiment, a U-phase coil unit 201 is arranged instead of the U-phase coil unit 1 of the stator of the fourth embodiment, a V-phase coil unit 301 is arranged instead of the V-phase coil unit 11, A W-phase coil unit 401 is arranged instead of the W-phase coil unit 21.

  As described above, by using the U-phase coil unit 201, the V-phase coil unit 301, and the W-phase coil unit 401, it is possible to reduce the height as compared with the stator of the fourth embodiment. In the case of the stator coil of the fourth embodiment, for example, when focusing on the fourth sides 1a, 11a, and 21a of each coil unit, the height of the fourth side 21a of the W-phase coil unit 21 is U-phase. It needs to be higher than the fourth side 1 a of the coil unit 1 and the fourth side 11 a of the W-phase coil unit 11. However, in the case of the fourteenth embodiment, the heights of the fourth side 401d of the W-phase coil unit 401, the fourth side 301d of the V-phase coil unit 301, and the fourth side 201d of the U-phase coil unit 201 are high. This is because the thicknesses can be substantially equal.

  In addition, although the coil unit used by Embodiment 11-14 mentioned above is comprised from three coils and each coil is 12 turns, it is not limited to these numbers, It changes suitably. Is possible.

  In the embodiment, the coil and coil unit of the present invention have been described by specifying the winding start portion and the winding end portion of the wire in consideration of the description of the manufacturing method using the coil manufacturing jig. However, the coil and the coil unit of the present invention include a coil and a coil unit that are not bound by the coil manufacturing jig and are rolled from the winding end portion toward the winding start portion, contrary to the above-described winding direction.

  In short, by arbitrarily selecting one of both ends of the wire, the lamination direction of the wire is determined.

  In addition, “substantially the same direction” in the present invention is within a range that is recognized as the same direction for social wisdom. It is within. Further, the “substantially vertical direction” in the present invention is within a range that is recognized as vertical by social wisdom, and the “substantially cylindrical shape” in the present invention is within a range that is recognized as cylindrical by social wisdom. That's it. In the present specification, “substantially” means a social convention.

  According to the coil manufacturing jig and the coil manufacturing jig of the present invention, the coil manufacturing method and the coil unit manufacturing method using them, the space factor is further improved, or the coil unit is not limited to the shape of the wire more easily. And a coil can be manufactured, which is useful as a stator, a rotor, an armature, and the like.

The perspective view of the U-phase coil unit in Embodiment 1 of this invention (A) Front view of U-phase coil unit according to Embodiment 1 of the present invention, (b) Top view of U-phase coil unit according to Embodiment 1 of the present invention, (c) U in Embodiment 1 of the present invention Right side view of phase coil unit, (d) Left side view of U phase coil unit in Embodiment 1 of the present invention The perspective view which separated the space | interval of each coil of the U-phase coil unit in Embodiment 1 of this invention intentionally for description. (A) Top view intentionally separated for the sake of explanation for the interval of each coil of the U-phase coil unit in Embodiment 1 of the present invention, (b) Each of the U-phase coil unit in Embodiment 1 of the present invention Side view with intentionally separated coil spacing for illustration FIG. 3 is a perspective view intentionally separated for the sake of explanation for the interval of 1 to 3 turns of the first coil of the U-phase coil unit according to Embodiment 1 of the present invention. (A) The front view which intentionally left | separated the space | interval of 1-3 turns of the 1st coil of the U-phase coil unit in Embodiment 1 of this invention for description, (b) In Embodiment 1 of this invention FIG. 3 is a top view intentionally separated for the sake of explanation of an interval of 1 to 3 turns of the first coil of the U-phase coil unit; (c) 1 to 1 of the first coil of the U-phase coil unit in Embodiment 1 of the present invention Left side view with intentional separation of 3 turns. The perspective view of the V phase coil unit in Embodiment 2 of this invention (A) Front view of V-phase coil unit according to Embodiment 2 of the present invention, (b) Top view of V-phase coil unit according to Embodiment 2 of the present invention, (c) V according to Embodiment 2 of the present invention. Right side view of phase coil unit, (d) Left side view of V phase coil unit in embodiment 2 of the present invention The perspective view which separated intentionally the space | interval of each coil of the V phase coil unit in Embodiment 2 of this invention for description. (A) A top view intentionally separating the intervals of the coils of the V-phase coil unit according to the second embodiment of the present invention for explanation, (b) each of the V-phase coil units according to the second embodiment of the present invention. Left side view with intentionally separated coil spacing for illustration The perspective view which separated intentionally the space | interval of 1-3 turns of the 1st coil of the V phase coil unit in Embodiment 2 of this invention for description. (A) Front view intentionally separating the first to third turns of the first coil of the V-phase coil unit in Embodiment 2 of the present invention for explanation, (b) in Embodiment 2 of the present invention. The top view which deliberately separated the 1st to 3rd turns of the 1st coil of the V phase coil unit for explanation, (c) 1 to 1 of the 1st coil of the V phase coil unit in Embodiment 2 of the present invention Left side view with intentional separation of 3 turns. The perspective view of the W phase coil unit in Embodiment 3 of this invention (A) Front view of W-phase coil unit according to Embodiment 3 of the present invention, (b) Top view of W-phase coil unit according to Embodiment 3 of the present invention, (c) W according to Embodiment 3 of the present invention. Right side view of phase coil unit, (d) Left side view of W phase coil unit in Embodiment 3 of the present invention The perspective view which separated intentionally the space | interval of each coil of the W phase coil unit in Embodiment 3 of this invention for description. (A) Top view intentionally separated for the sake of explanation of the interval of each coil of the W-phase coil unit in Embodiment 3 of the present invention, (b) Each of the W-phase coil unit in Embodiment 3 of the present invention Left side view with intentionally separated coil spacing for illustration The perspective view which separated intentionally the space | interval of 1-3 turns of the 1st coil of the W phase coil unit in Embodiment 3 of this invention for description. (A) The front view which intentionally left | separated the space | interval of 1-3 turns of the 1st coil of the W phase coil unit in Embodiment 3 of this invention for description, (b) In Embodiment 3 of this invention FIG. 3 is a top view in which the interval of 1 to 3 turns of the first coil of the W phase coil unit is intentionally separated for explanation, (c) 1 to 1 of the first coil of the W phase coil unit in Embodiment 3 of the present invention. Left side view with intentional separation of 3 turns. (A) The perspective view of the stator in Embodiment 4 of this invention, (b) The top view of the stator in Embodiment 4 of this invention, (c) The side view of the stator in Embodiment 4 of this invention (A) Plan view of stator in embodiment 4 of the present invention, (b) Slot enlarged view of stator core in embodiment 4 of the present invention, (c) Perspective view of stator in embodiment 4 of the present invention (A) Perspective view of U-phase coil unit manufacturing jig in Embodiment 5 of the present invention, (b) Perspective view of U-phase coil unit manufacturing jig and manufactured U-phase coil unit in Embodiment 5 of the present invention Figure (A) Front view of U-phase coil unit manufacturing jig in Embodiment 5 of the present invention, (b) Top view of U-phase coil unit manufacturing jig in Embodiment 5 of the present invention, (c) Right side view of U-phase coil unit manufacturing jig according to Embodiment 5 The exploded perspective view of the U phase coil unit manufacturing jig in Embodiment 5 of the present invention The figure for demonstrating the U-phase coil unit manufacturing method in Embodiment 6 of this invention The figure for demonstrating the U-phase coil unit manufacturing method in Embodiment 6 of this invention The figure for demonstrating the U-phase coil unit manufacturing method in Embodiment 6 of this invention (A) Front view of U-phase coil unit manufacturing jig and manufactured U-phase coil unit in Embodiment 6 of the present invention, (b) U-phase coil unit manufacturing jig and manufacturing in Embodiment 6 of the present invention The top view of the made U-phase coil unit, (c) The right side view of the U-phase coil unit manufactured in the U-phase coil unit manufacturing jig in Embodiment 6 of the present invention (A) Perspective view of V-phase coil unit manufacturing jig in Embodiment 7 of the present invention, (b) Perspective view of V-phase coil unit manufacturing jig and manufactured V-phase coil unit in Embodiment 7 of the present invention Figure (A) Back view of V-phase coil unit manufacturing jig in Embodiment 7 of the present invention, (b) Top view of V-phase coil unit manufacturing jig in Embodiment 7 of the present invention, (c) Left side view of V-phase coil unit manufacturing jig according to Embodiment 7 (A) Perspective view of V-phase coil unit manufacturing jig in Embodiment 7 of the present invention, (b) Disassembled perspective view of V-phase coil unit manufacturing jig in Embodiment 7 of the present invention The figure for demonstrating the V-phase coil unit manufacturing method in Embodiment 8 of this invention. (A) Back view of U-phase coil unit manufacturing jig and manufactured U-phase coil unit in Embodiment 8 of the present invention, (b) U-phase coil unit manufacturing jig and manufacturing in Embodiment 8 of the present invention (C) Left side view of the manufactured U-phase coil unit and the manufactured U-phase coil unit in Embodiment 8 of the present invention (A) Perspective view of W-phase coil unit manufacturing jig according to Embodiment 9 of the present invention, (b) Perspective view of W-phase coil unit manufacturing jig and manufactured U-phase coil unit according to Embodiment 9 of the present invention. Figure (A) Back view of the W-phase coil unit manufacturing jig in Embodiment 9 of the present invention, (b) Top view of the W-phase coil unit manufacturing jig in Embodiment 9 of the present invention, (c) FIG. Left side view of W-phase coil unit manufacturing jig in Embodiment 9 (A) A perspective view of a W-phase coil unit manufacturing jig in Embodiment 9 of the present invention, (b) An exploded perspective view of a W-phase coil unit manufacturing jig in Embodiment 9 of the present invention. (A) The figure for demonstrating the 4th groove | channel of the W phase coil unit manufacturing jig in Embodiment 9 of this invention, (b) 4th of the W phase coil unit manufacturing jig in Embodiment 9 of this invention. The figure for demonstrating a groove | channel, (c) The figure for demonstrating the 4th groove | channel of the W phase coil unit manufacturing jig in Embodiment 9 of this invention, (d) The W phase in Embodiment 9 of this invention The figure for demonstrating the 4th groove | channel of a coil unit manufacturing jig (A) The figure for demonstrating the spacer pressing jig of the W phase coil unit manufacturing jig in Embodiment 9 of this invention, (b) The spacer of the W phase coil unit manufacturing jig in Embodiment 9 of this invention Illustration for explaining the holding jig The figure for demonstrating the W-phase coil unit manufacturing method in Embodiment 10 of this invention. The figure for demonstrating the W-phase coil unit manufacturing method in Embodiment 10 of this invention. (A) Back view of W-phase coil unit manufacturing jig and manufactured U-phase coil unit in Embodiment 10 of the present invention, (b) W-phase coil unit manufacturing jig and manufacturing in Embodiment 10 of the present invention The top view of the made U-phase coil unit, (c) The left side view of the W-phase coil unit manufacturing jig and the manufactured U-phase coil unit in Embodiment 10 of the present invention (A) A plan view showing a modification of the U-phase coil unit manufacturing jig in Embodiment 5 of the present invention, (b) a side view showing a modification of the U-phase coil unit manufacturing jig in Embodiment 5 of the present invention. Figure A perspective view of a conventional stator Main part enlarged perspective view of a conventional stator Configuration diagram of a conventional winding device Configuration diagram of a strand discharge device in a conventional winding device The principal part expansion perspective view which showed only the U phase coil unit in the conventional stator The perspective view of the 1st coil of the U phase coil unit in Embodiment 1 of the present invention. The perspective view of the 1st coil of the V phase coil unit in Embodiment 2 of the present invention. The perspective view of the 1st coil of the W phase coil unit in Embodiment 3 of the present invention. The perspective view of the U-phase coil unit in Embodiment 11 of this invention (A) Front view of U-phase coil unit in Embodiment 11 of the present invention, (b) Top view of U-phase coil unit in Embodiment 11 of the present invention, (c) U in Embodiment 11 of the present invention Right side view of phase coil unit, (d) Left side view of U phase coil unit in Embodiment 11 of the present invention The perspective view of the 1st coil of the U phase coil unit in Embodiment 11 of this invention The perspective view of the V phase coil unit in Embodiment 12 of this invention (A) Front view of V-phase coil unit according to embodiment 12 of the present invention, (b) Top view of V-phase coil unit according to embodiment 12 of the present invention, (c) V according to embodiment 12 of the present invention Right side view of phase coil unit, (d) Left side view of V phase coil unit in Embodiment 12 of the present invention The perspective view of the 1st coil of the V phase coil unit in Embodiment 12 of this invention The perspective view of the W phase coil unit in Embodiment 13 of this invention (A) Front view of W-phase coil unit in embodiment 13 of the present invention, (b) Top view of W-phase coil unit in embodiment 13 of the present invention, (c) W in embodiment 13 of the present invention Right side view of phase coil unit, (d) Left side view of W phase coil unit in Embodiment 13 of the present invention The perspective view of the 1st coil of the W phase coil unit in Embodiment 13 of this invention The perspective view of the stator in Embodiment 14 of this invention

Explanation of symbols

1 U-phase coil unit 1a 1st side 1b 2nd side 1c 3rd side 1d 4th side 1e, 1f, 1g, 1h Bend 1i 1st direction 1j 2nd direction 1k 3rd direction 1l 4th direction 2 Flat wire 3 Beginning part 4 Ending part 5 Central space

Claims (45)

A coil having a shape having at least two sets of two opposing sides, formed by winding a single wire,
Of the two opposing sides, one is the first side and the other is the third side,
Of the other two opposite sides, one is the second side and the other is the fourth side,
The first side, the second side, the third side, and the fourth side are arranged in order based on the direction in which the wire is wound,
In each of the first side and the third side of the two sets, the stacking directions specified by the beginning and end of the wire rod are substantially the same direction.
Each of the specified stacking directions in the second and fourth sides of the other pair of the two sets is different from the one set of stacking directions.   The coil according to claim 1, wherein the stacking directions of the second side and the fourth side are substantially the same as each other and are substantially opposite to the set of stacking directions.   The coil according to claim 1, wherein the stacking directions of the second side and the fourth side are different from each other.   4. The coil according to claim 3, wherein the stacking directions of the second side and the fourth side are substantially opposite to each other and are substantially perpendicular to the set of stacking directions. The respective stacking directions in the second side and the fourth side are as follows:
The coil according to claim 3, wherein the coil has a direction larger than 90 degrees and smaller than 180 degrees with respect to the set of stacking directions.   The coil according to claim 1, wherein the wire is a flat wire.   The coil according to claim 6, wherein the flat wire is laminated in a thickness direction of the flat wire.   The coil according to claim 6, wherein a thickness and a width of the flat wire continuously change in the length direction.   The coil according to claim 6, wherein the rectangular wire has the same cross-sectional area at an arbitrary position in the length direction.   A coil unit in which a plurality of the coils according to claim 1 are continuously connected. Each of the first sides of the plurality of coils is disposed such that surfaces of the first sides are adjacent to each other.
Each of the third sides of the plurality of coils is arranged such that surfaces of the third sides are adjacent to each other.
When viewed from the vertical direction of the side surface of the second side, the side surfaces of the second side of each of the plurality of coils are at least partially overlapped with each other between the coils,
11. The coil unit according to claim 10, wherein when viewed from the vertical direction of the side surface of the fourth side, at least a part of the side surface of each of the fourth sides of the plurality of coils overlaps between the coils.   The coil unit according to claim 11, wherein the number of stacked wires is the same in the first side and the third side of all of the plurality of coils. The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
12. The coil unit according to claim 11, wherein a width of the wire in a direction perpendicular to a stacking direction of the wires in each of the first side and the third side is equal to or less than a width of the slot. The first side and the third side are the coil units inserted into slots of a rotor disposed inside a substantially cylindrical stator,
12. The coil unit according to claim 11, wherein a width of the wire in a direction perpendicular to a stacking direction of the wires in each of the first side and the third side is equal to or less than a width of the slot. The first side and the third side are the coil units that are inserted into slots of a stator disposed inside a substantially cylindrical outer rotor,
12. The coil unit according to claim 11, wherein a width of the wire in a direction perpendicular to a stacking direction of the wires in each of the first side and the third side is equal to or less than a width of the slot. A shape having at least a set of two opposing sides formed by winding one wire, one of the two opposing sides being a first side and the other being a third side, Of the two opposite sides, one is the second side and the other is the fourth side, and the first side, the second side, the third side, and the fourth side are based on the direction in which the wire is wound Are coil manufacturing jigs for manufacturing coils, which are arranged in order,
A first groove for laminating the wire and forming the first side, a second groove for laminating the wire and forming the second side, and laminating the wire to form the third side A third groove for laminating and a fourth groove for laminating the wire and forming the fourth side, comprising a jig body arranged in order along the direction of winding the wire,
The direction toward the bottom surface of each of the first groove and the third groove is substantially the same direction.
The direction toward the bottom surface of each of the second groove and the fourth groove is different from the direction toward the bottom surfaces of the first groove and the third groove.
The coil manufacturing jig which the both ends in the length direction of each said groove | channel are open | released. The direction toward the bottom surface of each of the second groove and the fourth groove is substantially the same direction.
The coil manufacturing jig according to claim 16, wherein the direction is substantially opposite to a direction toward the bottom surfaces of the first groove and the third groove.   The coil manufacturing jig according to claim 16, wherein directions of the second groove and the fourth groove toward the bottom surface are different from each other. The directions toward the bottom surfaces of the second groove and the fourth groove are opposite to each other.
The coil manufacturing jig according to claim 18, wherein the coil manufacturing jig is substantially perpendicular to a direction toward a bottom surface of the first groove and the third groove.   The direction toward the bottom surface of each of the second groove and the fourth groove is greater than 90 degrees and smaller than 180 degrees with respect to the direction toward the bottom surfaces of the first groove and the third groove. The coil manufacturing jig according to claim 18.   The coil manufacturing jig according to claim 16, wherein a side wall of at least one of the first to fourth grooves is detachable from the jig body. (1) A plurality of coils having a shape having at least two sets of two opposing sides formed by winding one wire are continuously connected, and (2) Of the two opposing sides, One is a first side and the other is a third side. (3) Of the two opposite sides, one is a second side and the other is a fourth side. (4) The first side and the second side. A coil unit manufacturing jig for manufacturing a coil unit, wherein the side, the third side, and the fourth side are sequentially arranged based on a direction in which the wire is wound,
A first groove for laminating the wire and forming the first side, a second groove for laminating the wire and forming the second side, and laminating the wire to form the third side A third groove for laminating and a fourth groove for laminating the wire and forming the fourth side, comprising a jig body arranged in order along the direction of winding the wire,
The directions toward the bottom surfaces of the first groove and the third groove are substantially the same direction,
The directions toward the bottom surfaces of the second groove and the fourth groove are different from the directions toward the bottom surfaces of the first groove and the third groove,
Each width in the second groove and the fourth groove is a length capable of arranging the plurality of wires in parallel in the width direction,
A coil unit manufacturing jig in which both ends in the length direction of each groove are open. The depths of the second groove and the fourth groove are larger than the product of the maximum number of layers of each of the plurality of coils and the width of the wire in the stacking direction,
The depth of the said 1st groove | channel and the said 3rd groove | channel is a coil unit manufacturing jig of Claim 22 larger than the product of all the lamination | stacking numbers of these coils, and the width | variety of the said wire in the said lamination direction.   The coil unit manufacturing jig according to claim 22, wherein one side wall of the second groove and / or the fourth groove is movable so that the groove width can be adjusted.   The coil unit manufacturing jig according to claim 22, wherein a side wall of at least one of the first to fourth grooves is detachable from the jig body.   23. The coil unit manufacturing jig according to claim 22, wherein all or part of one side wall of each of the second groove and the fourth groove is a side surface of the second side and the fourth side of the coil formed immediately before. .   The coil unit manufacturing jig according to claim 22, further comprising a detachable spacer that forms one side wall of the second groove and / or the fourth groove. A coil manufacturing method using the coil manufacturing jig according to any one of claims 16 to 21,
The wire is disposed from an arbitrary position of any one of the first to fourth grooves, and is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, Arranged from the other open end of the groove to the next groove through one open end of the next groove, and from the other open end of the groove to the next groove through the one open end of the next groove And a coil manufacturing method comprising a step of repeating a squeezing step of disposing from the other open end of the groove through the one open end of the predetermined groove to a position before the arbitrary position of the predetermined groove a predetermined number of times . The wire is a flat wire,
Arranging the wire in any one of the first to fourth grooves is to arrange the bottom surface of the groove and the surface having the width of the rectangular wire to face each other.
When the wire is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, the wire rod is twisted or after being twisted, 29. The coil manufacturing method according to claim 28, wherein the coil is disposed such that a bottom surface and a surface having a width of the flat wire are opposed to each other. The predetermined groove is the first groove,
29. The coil manufacturing method according to claim 28, wherein the predetermined number of times of squeezing step is a step of performing at least the arrangement of the wire in the third groove. A coil unit manufacturing method using the coil unit manufacturing jig according to any one of claims 22 to 27,
The wire is disposed from an arbitrary position of any one of the first to fourth grooves, and is disposed in the next groove from one open end of the predetermined groove through one open end of the next groove, Arranged from the other open end of the groove to the next groove through one open end of the next groove, and from the other open end of the groove to the next groove through the one open end of the next groove And a coil manufacturing step including a step of repeating a squeezing step of disposing from the other open end of the groove through one open end of the predetermined groove to a position before the arbitrary position of the predetermined groove a predetermined number of times. A unit repetition step that repeats the number of times corresponding to the number of the plurality of coils,
The squeezing step in the next coil manufacturing step after the coil manufacturing step is adjacent to the second side and the fourth side of the coil formed in the coil manufacturing step in the second groove and the fourth groove. The coil unit manufacturing method, which is a step of arranging the wire.   After the coil manufacturing step, when the next coil manufacturing step is performed, the side wall is moved to further secure the width of the second side and / or the fourth side for the next coil. The coil unit manufacturing method according to claim 31.   32. The coil unit manufacturing method according to claim 31, further comprising a removing step of removing the one side wall and removing the wound wire after the unit repeating step.   32. The coil unit manufacturing method according to claim 31, further comprising a step of inserting the spacer when performing a next coil manufacturing step after the coil manufacturing step.   35. The method according to claim 34, further comprising the step of securing the second groove and / or the fourth groove for the next coil including the width of the spacer by moving the side wall after the coil manufacturing step. Coil unit manufacturing method. A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
A stator comprising: the coil unit according to claim 13, wherein the first side and the third side are each attached to the core by being inserted into the two slots. A rotor core having a plurality of cores and slots disposed inside a substantially cylindrical stator core;
The rotor including the coil unit according to claim 14, wherein the first side and the third side are each attached to the core by being inserted into the two slots. A stator core having a plurality of cores and slots disposed inside a substantially cylindrical outer rotor;
The stator comprising: the coil unit according to claim 15, wherein the first side and the third side are each attached to the core by being inserted into the two slots. A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
The coil unit according to claim 11, which is used as a U-phase coil unit in which the coils according to claim 2 are connected,
The coil unit according to claim 11 used as a V-phase coil unit in which the coils according to claim 5 are connected,
The coil unit according to claim 11, wherein the coil according to claim 4 is connected, and is used as a W-phase coil unit.
The W-phase coil unit, the U-phase coil unit, and the V-phase coil unit are attached to the core by inserting each of the first side and the third side into the slot,
The stator formed so that the direction which the wire of the 2nd side and the 4th side of the V phase coil unit overlaps does not interfere with the U phase coil unit and the W phase coil unit. Each of the coils in the plurality of coils has a stacking direction in each of the second side and the fourth side that is substantially opposite to each other and is substantially perpendicular to the set of stacking directions. And
The side surface of the second side is adjacent between the continuously connected coils,
The coil unit according to claim 11, wherein a side surface of the fourth side is adjacent between the continuously connected coils.   41. The coil according to claim 40, wherein each of the second side and the fourth side of the plurality of coils is arranged from one surface of the first side of the coil unit or from the other surface. unit.   41. The coil unit according to claim 40, wherein each of the second side and the fourth side of the plurality of coils is arranged closer to the coil at the center of the first side of the coil unit. The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
The width of the wire in the direction perpendicular to the stacking direction of the wires in each of the first side and the third side is equal to or less than the width of the slot;
42. The coil unit according to claim 41, wherein the second side and the fourth side are arranged from an outer peripheral side of the stator. The first side and the third side are the coil units inserted into slots of a substantially cylindrical stator,
The width of the wire in the direction perpendicular to the stacking direction of the wires in each of the first side and the third side is equal to or less than the width of the slot;
42. The coil unit according to claim 41, wherein the second side and the fourth side are arranged from an inner peripheral side of the stator. A substantially cylindrical stator core having a plurality of cores and slots formed toward the cylindrical central axis;
The coil unit according to claim 43, which is used as a U-phase coil unit;
The coil unit according to claim 42 used as a V-phase coil unit;
The coil unit according to claim 44, wherein the coil unit is used as a W-phase coil unit.
The U-phase coil unit, the V-phase coil unit, and the W-phase coil unit are attached to the core by inserting the first side and the third side into the slot,
The U-phase coil unit is disposed from the outer peripheral side of the stator, the W-phase coil unit is disposed from the inner peripheral side of the stator, and the V-phase coil unit includes the U-phase coil unit and the V-phase coil unit. Between the phase coil units,
The stator in which the heights of the second side and the fourth side of the U-phase coil unit, the V-phase coil unit, and the W-phase coil unit are the same.

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