JP2008182867A - Coil manufacturing method and coil, armature manufacturing method - Google Patents

Abstract

A coil conductor can be easily wound at a high space factor while preventing disturbance.
(A) A step of winding one end side of a coil conducting wire 12 in an aligned manner from one end face 24a toward the other end face 25a from the other end face 25a to a position before leaving a margin width; (B) winding the other end side of the coil conducting wire 12 between the winding portion on one end side of the coil conducting wire 12 wound in the step (a) and the other end face 25a; It is equipped with.
[Selection] Figure 2

Description

  The present invention relates to a technique for manufacturing a coil applied to an axial gap type motor or the like.

  Even if the axial gap type motor is made thin in the direction of the rotation axis, the magnetic pole surface of the permanent magnet for the field can be widened, and the space factor of the winding can be easily increased. Torque and output can be increased. In recent years, with the advancement of materials such as dust cores, coils can be provided around the magnetic core to achieve high magnetic permeability, and research is also being promoted for high output motors applied to compressors etc. Yes.

  As a coil applied to such an axial gap type motor or the like, a winding method for winding a coil conductor wire with a high space factor includes aligned winding. However, even in the aligned winding, it is necessary to draw out the winding start portion of the coil conducting wire outward. For this reason, when winding the coil conductor in the outermost layer than the innermost layer, it is necessary to avoid the winding start portion of the coil conductor that is drawn outward. Then, in the layer on the outer peripheral side than the innermost peripheral layer, the coil conductor cannot be wound for at least one turn per layer, or the aligned winding is disturbed, which causes a reduction in the space factor of the coil conductor. There was a problem.

  As technologies related to the present invention, there are Patent Literature 1 and Patent Literature 2.

  In Patent Document 1, two coils are arranged in two stages along a predetermined axial direction. And the winding start of the coil conducting wire of each coil is connected through the connection piece on the inner peripheral side of each coil.

  Patent Document 2 discloses a method in which a predetermined number of turns in a winding start of a coil winding is wound in the outer peripheral direction and pulled out to the outer peripheral portion, and then the winding end side of the coil winding is aligned and wound.

JP-A-62-201030 Japanese Utility Model Publication No. 63-51540

  However, in patent document 1, since a connection piece exists in the inner peripheral side of each coil, there exists a possibility that a winding form may be disturb | confused by the connection piece. In particular, the connection piece needs to have a certain length and thickness in order to perform a connection operation to the winding start end of the coil conductor. Moreover, the connection piece needs to have an insulation structure with respect to the coil conducting wire on the outer peripheral side. By these various configurations, there is a possibility that the winding form may be disturbed particularly by the connection piece.

  Further, in Patent Document 2, when a predetermined number of turns are wound around the first row of the coil winding in the outer circumferential direction, the winding form of the second and subsequent layers is destroyed when a certain tension is applied. . In particular, the current state of such collapse is unavoidable in coil conductors having a substantially circular cross section.

  In order to avoid this, it is conceivable to provide temporary holding means for maintaining the winding form when a predetermined number of turns of the winding start of the coil winding are wound in the outer circumferential direction. However, even if it thinks in this way, at the time of removing a temporary holding means, the process of fixing the winding part of the winding start of a coil winding with an adhesive etc. is needed, and a manufacturing process becomes complicated.

  Then, an object of this invention is to enable it to wind a coil conducting wire easily by a high space factor, preventing disorder.

  In order to solve the above-described problem, this coil manufacturing method is such that a coil conductor (12) is wound around a predetermined axis (28) between a pair of opposed end faces (25a, 25b) having a predetermined width. (A) One end side of the coil conducting wire (12) is directed from one end face (25a) to the other end face (25b), and the other of the coil conductors (10, 56) is manufactured. A step of winding in an aligned manner from the end face (25b) to a position before leaving a margin width; and (b) the coil conductor wound around the other end of the coil conductor (12) in the step (a). (12) and a step of winding between the winding portion on one end side and the other end face (25b).

  In order to solve the above-mentioned problem, another method for manufacturing a coil is as follows. A coil conductor (12) is placed around a predetermined axis (25) between a pair of opposite end faces (25a, 25b) having a predetermined width. (A) One end side of the coil conducting wire (12) is directed from one end face (25a) to the other end face (25b), A step of winding in an aligned manner from the other end face (25b) to a position before leaving a margin width; and (b-1) winding the other end side of the coil conductor (12) in the step (a). A step of winding the coil conductor (12) between one end side of the coil conductor (12) and the other end face, and further winding the coil conductor (12) on the outer peripheral side; and (c) the coil conductor (12) One end side of the coil conductor wire (12) wound in the step (a) is wound on one end side. Winding the coil conductor wire (12) wound in the step (b-1) on the outer peripheral side of the portion in an aligned manner from the wound portion on the other end side toward the one end face; Prepare.

  In these cases, the coil conductor (12) may be wound directly around the magnetic core (20, 54).

  Moreover, in the manufacturing method of the armature (50) provided with two or more coils (56) manufactured by the said manufacturing method of each said coil, at least one of the said several coils (56) is made to another coil (56). The coil conductor wire is wound in a state separated from the other coil), and then combined with the other coil (56).

  Moreover, after winding the said coil conducting wire around the winding frame body (60) different from a magnetic core (54), it is good to mount | wear with the said magnetic core (54).

  Moreover, the said winding frame body (60) may be mounted | worn with the said magnetic core (56) with the said coil (54) as an insulator.

  Moreover, it is good to adhere | attach the said coil conducting wire wound by the said winding frame body during winding after the said winding frame body, or after winding.

  In addition, a self-bonding wire is used as the coil conductor, and the coil conductors wound around the winding frame body may be bonded to each other during or after being wound around the winding frame body.

  Further, the coil conductor (12) is turned by turning the first nozzle (30) around the predetermined axis (28) while supplying one end side of the coil conductor (12) from the first nozzle (30). And rotating the second nozzle (32) around the predetermined axis (28) while supplying the other end side of the coil conductor (12) from the second nozzle (32), It is good to wind the other end side of the said coil conducting wire (12).

  Further, the other end of the coil conducting wire is fixed to the connecting portion (36), and the connecting portion (36) is swung around the predetermined axis (28), whereby the coil conducting wire (12) The end of the other end is wound, and the first nozzle (30) is turned around the predetermined axis (28) while supplying one end of the coil conductor (12) from the first nozzle (30). In this case or by rotating the wound object (20), it is preferable to wind one end side of the coil conductor (12).

  Moreover, the one end side (112a) of the said coil conducting wire and the other end side (112b) of the said coil conducting wire may be pulled out from the winding part from the said other end surface (125a).

  The coil is a coil in which a coil lead wire (12) is wound around a predetermined axis (28) between a pair of opposing end faces (24a, 24b) having a predetermined width. The conducting wire (12) is wound in an aligned manner over a plurality of layers from one end face (24a) to the other end face (25a), from the other end face (25a) to the front leaving a margin. A first winding portion (14a) and a second winding portion (14b) wound in a plurality of layers along the other end surface (25a), along the predetermined axis (28). In at least one cross-section, at least one position of the cross-section of the coil conductor (12) constituting the second winding portion (24b) is the layer outside the first winding portion (14a). From the cross-sectional position of the coil conductor (12) constituting In which is disposed at a position overlapping on the inside.

  According to this coil manufacturing method, one end side of the coil conductor wire is wound in an aligned manner from one end face toward the other end face and from the other end face to a position before leaving a margin. In order to wind the other end side of the conducting wire between the wound portion on one end side of the coiled conducting wire and the other end face, the other end side of the coil conducting wire is wound on the coiled conducting wire. It is stable and hardly collapses between the winding part on one end side of the slab and the other end face. Therefore, the coil conductor can be easily wound at a high space factor while preventing disturbance.

  Further, according to another coil manufacturing method, one end side of the coil conducting wire is wound in an aligned manner from one end face to the other end face, from the other end face to a position where a margin width is left. The other end side of the coil conductor wire is wound between one end side of the wound coil conductor wire and the other end surface, and further wound on the outer peripheral side, Align one end side of the coil lead wire from the winding portion on the other end side of the wound coil lead wire toward the one end surface on the outer peripheral side of the wound portion on the one end side of the coil lead wire. It is wound in a shape. For this reason, the other end side of the coil conducting wire is stable between the wound portion on one end side of the wound coil conducting wire and the other end face and is not easily broken. Therefore, the coil conductor can be easily wound at a high space factor while preventing disturbance.

  In these cases, when the coil conductor is directly wound around the magnetic core, the coil conductor can be strongly wound. Here, winding the coil conductor directly around the magnetic core means to eliminate the method of winding the coil conductor at a place not around the magnetic core, and therefore the coil conductor around the insulator around the magnetic core. Including the case of winding

  Further, after winding the coil conductor in a state where at least one of the plurality of coils is separated from the other coil, the coil conductor is integrated by combining with the other coil. A method for manufacturing a coil that is wound directly around an insulator around a magnetic core can be easily applied to an armature having a plurality of coils.

  In addition, when the coil conductor is wound around a winding body different from the magnetic core and then attached to the magnetic core, the coil conductor can be wound without being restricted by the location of the magnetic core.

  In addition, when the winding body is attached to the magnetic core together with the coil as an insulator, the coil body may be attached to the magnetic core as it is after winding the coil lead wire, so that the manufacture thereof is easy.

  Further, when the coil conductors wound around the winding frame are bonded to each other during or after winding on the winding frame, the winding frame can be omitted.

  Further, a self-bonding wire is used as the coil conductor, and the coil conductors wound around the winding frame body are bonded to each other during or after being wound around the winding frame body. The frame can be omitted.

  Further, the one end side of the coil conducting wire is wound around the predetermined axis while the one end side of the coil conducting wire is supplied from the first nozzle, so that one end side of the coil conducting wire is wound and the other end side of the coil conducting wire is When the other end side of the coil conductor is wound by turning the second nozzle around the predetermined axis while supplying from the second nozzle, the one end side and the other end side of the coil conductor are wound in the opposite direction. can do.

  Further, the other end of the coil conductor is fixed to a connecting portion, and the connecting portion is turned around the predetermined axis to wind the end of the other end of the coil conducting wire. While one end side of the conducting wire is supplied from the first nozzle, the one end side of the coil conducting wire is wound by turning the first nozzle around the predetermined axis or rotating the wound object. As a result, the coil conductor can be wound with a simple configuration with fewer nozzles.

  Moreover, when the one end side of the said coil conducting wire and the other end side of the said coil conducting wire are drawn out from the winding part from the said other end surface, a coil conducting wire can be wound to the outermost periphery layer fully. Moreover, since the one end side of the said coil conducting wire and the other end side of the said coil conducting wire are pulled out from the substantially the same location, it is excellent in handling property, such as subsequent connection of the coil conducting wire end becomes easy.

  Further, according to this coil, the coil conductor wire is wound in an aligned manner over a plurality of layers from one end face to the other end face, from the other end face to the front leaving a margin width. A winding portion and a second winding portion wound in a plurality of layers along the other end surface, and the second winding portion is configured in at least one cross section along the predetermined axis. Since at least one position of the cross section of the coil conductor wire is disposed at a position overlapping the inside of the cross sectional position of the coil conductor wire constituting the first winding portion in the outer layer, the coil It can be said that the coil is manufactured by the manufacturing method. For this reason, similarly to the above, it is possible to provide a coil in which a coil conductor is easily wound with a high space factor while preventing disturbance.

{First embodiment}
Hereinafter, the manufacturing method of the coil which concerns on 1st Embodiment is demonstrated. FIG. 1 is a perspective view showing a manufactured coil.

  This coil 10 is obtained by winding a plurality of layers of a coil conducting wire 12 around a predetermined axis 28 between opposing end surfaces having a predetermined width L. Here, the coil 10 has a magnetic core 20 and a coil winding portion 16 around which the coil conducting wire 12 is wound.

  The magnetic core 20 has a substantially cylindrical magnetic core body 22 and flanges 24 and 25 provided at both ends of the magnetic core body 22. At least a portion of the magnetic core body 22 of the magnetic core 20 is formed of a soft magnetic material that is stretched along the direction of the predetermined axis 28. The magnetic core body 22 is not limited to a substantially cylindrical shape, and may be a substantially elliptical columnar shape, a polygonal cylindrical shape such as a substantially triangular columnar shape or a substantially rectangular columnar shape. In addition, since the end surfaces 24a and 25a should just exist at the time of winding the coil conducting wire 12, the structure removed after winding the coil conducting wire 12 may be sufficient.

  Each of the flange portions 24 and 25 is formed in a plate shape that spreads outward from the outer peripheral surface of the end portion of the magnetic core 20, in this case, a substantially circular plate shape. Inward end surfaces 24a and 25a (respectively facing surfaces) of the flange portions 24 and 25 are formed on flat surfaces extending in an annular shape, and are in a substantially parallel positional relationship. The distance between the end faces 24a and 25a is a predetermined width L.

  The coil 10 is manufactured by winding a coil conductor such as an enamel wire around the magnetic core 20 to form the coil winding portion 16.

  In the present embodiment, an example of winding around the magnetic core 20 will be described. However, the winding may be wound around a bobbin-shaped winding frame having a flange similar to the flanges 24 and 25.

  The coil 10 as described above is used, for example, as an armature of an axial gap type rotating machine, and a specific configuration example thereof will be described later.

  FIG. 2 is an explanatory view showing a coil manufacturing method. In FIG. 2, only one side portion of the winding portion 16 of the coil 10 with respect to the predetermined shaft 28 is shown in a cross section cut along the direction of the predetermined shaft 28. Moreover, in FIG. 2, the number described in the cross section which shows the coil conducting wire 12 has shown the winding order.

  The method of manufacturing the coil 10 includes: (a) winding one end side of the coil conductor wire 12 from one end surface 24a toward the other end surface 25a in an aligned manner from the other end surface 25a to a position where a margin width is left. And (b) winding the other end side of the coil conducting wire 12 between the winding portion on one end side of the coil conducting wire 12 wound in the step (a) and the other end face. And a step of performing.

  Here, the one end side and the other end side of the coil conducting wire 12 are based on a portion of the coil conducting wire 12 that has already been wound or a portion that is scheduled to be wound next (when it is wound first). Yes. Moreover, when observing in the winding form of the coil conductor 12 that closes the majority of the coil 10, it can be understood that one end of the coil conductor 12 is a winding end portion and the other end of the coil conductor 12 is a winding start portion.

  The method for manufacturing the coil will be described more specifically.

  First, as shown in FIG. 3, a substantially intermediate portion of the coil conductor 12 is hooked around the magnetic core body 22 of the magnetic core 20 so as to circulate about a half turn. At this time, the coil conducting wire 12 is disposed around the magnetic core main body 22 and at a position from the other end face 25a. Specifically, it is disposed along the corner where the main body 22 and the end face 25a intersect. Further, a predetermined length, that is, a length that can be wound around the magnetic core main body 22 a plurality of times, is secured on the other end side of the coil conducting wire 12. Then, one end side of the coil conductor 12 is aligned from the other end face 25a to the one end face 24a (from the left side to the right side in FIG. 2), that is, the coil conductors 12 on each adjacent circumference are densely arranged. Wrap it so that it is parallel to the next. The winding direction on one end side of the coil conducting wire 12 at this time is clockwise (clockwise) when viewed from the other end face 25a toward the one end face 24a. As a result, the coil conductor 12 is wound around the magnetic core main body 22 and substantially between the both end faces 25a and 24a by a further number of turns (coil conductors with numerals "1" to "8" in FIG. 2). 12 cross section). In this state, one end side of the coil conducting wire 12 is drawn out on one end face 24a side of the magnetic core 20, and the other end side of the coil conducting wire 12 is drawn out on the other end face 25a of the magnetic core 20.

  Subsequently, the second layer is counted from the inner peripheral side. First, the one end side of the coil conducting wire 12 is wound in an aligned manner from one end face 24a to the other end face 25a. Here, the second layer coil conductor 12 is wound in a stacked manner, that is, between each turn of the first layer coil conductor 12. This saddle-like winding form has the merit that the space between the coil conductors 12 can be reduced and the space factor can be improved. Then, the winding on one end side of the coil conductor 12 is stopped with the effort of leaving a margin from the other end face 25a (see the cross section of the coil conductor 12 denoted by numerals “9” to “15” in FIG. 2). Thereby, the said process (a) is implemented. The margin width is a width that allows the other end of the coil conductor 12 to be wound about one turn, and is a width that is less than twice the diameter of the coil conductor 12 from about the diameter of the coil conductor 12. Here, the margin width is about 1.5 times the diameter of the coil conductor 12.

  In the above state, the other end side of the coil conducting wire 12 is connected to the winding portion on one end side of the coil conducting wire 12 wound in the step (a) (a coil with numerals “9” to “15” in FIG. 2). Winding for one turn is performed between the other end face 25a (see the cross section of the coil lead wire 12 with the numeral “16” in FIG. 2). Thereby, the said process (b) is implemented and winding of the 2nd layer is complete | finished. Note that the winding direction on the other end side of the coil conducting wire 12 is opposite to the winding direction on the one end side of the coil conducting wire 12, that is, when viewed from the other end face 25a toward the one end face 24a, it is counterclockwise. (Counterclockwise).

  Subsequently, the third layer is wound. That is, between the winding part on one end side of the coil conducting wire 12 wound in the step (a) and the other end surface 25a, the coil conducting wire 12 wound one turn further on the outer peripheral side on the other end side. Then, the other end side of the coil conductor 12 is wound by one turn along the other end face 25a (see the cross section of the coil conductor 12 denoted by numeral “17” in FIG. 2). Step (b-1) is performed by the steps up to here after step (a).

  Furthermore, the coil conducting wire 12 wound in the step (b-1) on one end side of the coil conducting wire 12 on the outer peripheral side of the winding portion on the one end side of the coil conducting wire 12 wound in the step (a). Are wound in an aligned manner from the winding portion on the other end side toward one end surface 24a (see the cross section of the coil conductor 12 denoted by numerals "18" to "24" in FIG. 2). Thereby, the winding of the third layer is completed, and the step (c) is performed.

  By repeating the steps (a) to (c), the coil conductor 12 can be wound over a plurality of layers. Further, when both end sides of the coil conducting wire 12 are pulled out, they can be pulled out from the winding layer on the outer peripheral side without disturbing the winding form.

  In the manufacturing method of the coil 10 configured as described above, the other end side of the coil conducting wire 12 is arranged between the winding portion on one end side of the coil conducting wire 12 wound in the step (a) and the other end face 25a. Therefore, the winding form is stable during the work and after the work, and hardly collapses. Therefore, the coil conductor 12 can be easily wound in an array with a high space factor while preventing disturbance.

  Further, when the next layer is wound, the coil conductor 12 wound by one turn is wound between the wound portion on one end side of the coil conductor 12 wound in the step (a) and the other end face 25a. The other end side of the coil conducting wire 12 is wound along the other end face 25a on the outer peripheral side of the other end side, and then, one end side of the coil conducting wire 12 is wound. For this reason, also when winding a next layer, the other end side of the coil conducting wire 12 is stable and does not collapse easily. Therefore, the coil conducting wire 12 can be easily wound at a high space factor while preventing disturbance over a plurality of layers.

  In addition, the manufacturing method of the coil 10 provided with process (a) and (b) is applicable if the coil conducting wire 12 is wound two or more layers. However, the effect of increasing the space factor is greater as the coil conductor 12 is wound in more layers.

  FIG. 4 shows another winding form of the coil conducting wire. FIG. 4 shows an aspect in which the coil conductor 12 of the next layer is wound on each turn of the coil conductor 12. That is, FIG. 2 shows a configuration in which the coil conductors 12 are wound in a stacked manner. However, when the coil conductor 12 moves from a predetermined layer to the next layer, the coil conductors 12 of the predetermined layer and the next When there is a portion where the coil conductor wire 12 of the layer intersects, it is not possible to make all the stacked winding form shown in FIG. 2, but the stacked winding form shown in FIG. 4 and the winding form shown in FIG. In this case, the winding form shown in FIG. 4 is shown in the partial cross section along the predetermined axis | shaft 28, and the winding form shown in FIG. 2 is shown in another cross section. For example, when the coil 10 is formed in a polygonal column shape, the coil conductor 12 exhibits a winding form shown in FIG. 4 in a cross section corresponding to one surface where a predetermined layer moves from a predetermined layer to the next layer. It is conceivable that the configuration of the winding form shown in FIG.

  By the way, the stacked winding form shown in FIG. 2 is wound in an aligned manner over a plurality of layers from one end face 24a toward the other end face 25a, from the other end face 25a to the front with a margin left. It has the 1st winding part 14a rotated and the 2nd winding part 14b wound by multiple layers along the other end surface 25a. Then, in a cross section along the predetermined axis 28, at least one position (for example, a number indicated by “16” in FIG. 2) of the cross section of the coil conductor 12 constituting the second winding portion 14b is present. In the outer layer, the coil winding wire 12 constituting the first winding portion 14a is disposed at a position overlapping the inner side of the cross-sectional position (for example, the number “18” in FIG. 2). Yes.

  Therefore, in at least one cross section along the predetermined axis 28, the coil 10 including the winding form according to the positional relationship as described above is obtained by alternately winding the one end side and the other end side of the coil conducting wire 12. It can be said that it was manufactured by the manufacturing method.

  But substantially the whole coil 10 manufactured with the said manufacturing method may be unified by the winding form shown in FIG. 2 or FIG.

  Note that which part of the coil 10 exhibits the winding form shown in FIG. 2 or FIG. 4 can be set to an arbitrary position by adjusting the moving position of the coil conductor 12 to the next layer. For example, in a form in which the coil 10 is incorporated in an axial gap type rotating machine to be described later, it is preferable to form a winding form with a high space factor as shown in FIG. .

  FIG. 5 is a diagram illustrating an example of a method of winding a coil conductor. First, a pair of first nozzles 30 and second nozzles 32 for supplying the coil conductor 12 are prepared. Each of the first nozzle 30 and the second nozzle 32 is provided with a wound container or the like in which one end side and the other end side of the single coil conductor 12 are wound and accommodated. Then, one end side and the other end side of the coil conducting wire 12 are continuously supplied from the first nozzle 30 and the second nozzle 32. Further, each of the first nozzle 30 and the second nozzle 32 is configured to be rotatable around the axis 28 of the magnetic core 20 fixed at a fixed position by a turning mechanism (not shown) or the like. Then, one end side of the coil conducting wire 12 is wound around the magnetic core 20 by turning the first nozzle 30 around the predetermined axis 28 in a predetermined direction while continuously supplying one end side of the coil conducting wire 12 from the first nozzle 30. It has come to be. At this time, one end side of the coil conductor 12 is wound around the magnetic core 20 in an aligned manner by gradually moving the first nozzle 30 along the predetermined axis 28 direction while turning. On the other hand, while the other end side of the coil conducting wire 12 is continuously supplied from the second nozzle 32, the second nozzle 32 is turned around the predetermined axis 28 in the direction opposite to the above so that the other end side of the coil conducting wire 12 is It is wound around the magnetic core 20. By rotating the first nozzle 30 and the second nozzle 32 alternately according to the manufacturing method, the one end side and the other end side of the coil conducting wire 12 are wound in opposite directions, respectively, and the manufacturing method can be carried out.

  FIG. 6 is a diagram illustrating another example of a method of winding a coil conductor. Since the other end side of the coil conducting wire 12 is wound about one turn for each layer, the required length is relatively short. Thus, it is not always necessary to supply from the nozzle as described above. Here, a predetermined required length is secured in advance on the other end side of the coil conducting wire 12, and a connection portion 36 such as a terminal for connection to the outside is connected to the end portion. And the other end side of the coil conducting wire 12 is wound around the magnetic core 20 by fixing and holding the connecting portion 36 on a turning mechanism or the like and turning it around the magnetic core 20. In addition, about the one end side of the coil conducting wire 12, it winds using the 2nd nozzle 32 similarly to the above.

  Thereby, the 1st nozzle 30 is abbreviate | omitted and the one end side and other end side of the coil conducting wire 12 can be wound in the reverse direction by a comparatively simple structure.

  In each of the above methods, the magnetic core 20 side may be rotated. As a matter of course, various methods including a method used by those skilled in the art as a coil manufacturing method can be adopted as a method of winding the coil conductor 12.

{Second Embodiment}
An axial gap type rotating machine according to the second embodiment will be described. FIG. 7 is an exploded perspective view showing an axial gap type rotating machine incorporating a coil manufactured by the manufacturing method according to the first embodiment.

  The axial gap type rotating machine 40 includes one field element 42 and two armatures 50 and 50.

  The field element 42 is formed in a substantially disk shape, and is rotatably supported around a predetermined rotation shaft 48 by a rotation shaft portion (not shown). The armatures 50 and 50 are formed in a substantially disc shape, and are arranged at fixed positions on both sides of the field element 42 in the direction of the rotation axis 48 with a gap therebetween.

  The field element 42 has a plurality of permanent magnets 44 disposed around the rotation axis 48, and magnetic pole faces having alternating magnetism around the rotation axis 48 are provided on both sides thereof.

  Each armature 50 has a back yoke magnetic core 52, a plurality of magnetic cores 54, and a plurality of coils 56. The back yoke magnetic core 52 is made of a magnetic material, and is formed in a substantially disk shape with a hole 52h formed in a substantially central portion. The back yoke magnetic core 52 supports the magnetic core 54 on the opposite side of the field element 42.

  The magnetic cores 54 are annularly arranged on the surface of the back yoke magnetic core 52 on the field element 42 side at intervals along the circumferential direction around the rotation shaft 48. Each magnetic core 54 is formed in a thick plate shape having a shape obtained by rounding the vertices of an isosceles triangle shape on a plane substantially orthogonal to the rotation shaft 48, and becomes gradually wider outward from the rotation shaft 48. It is arranged in a posture. A coil 56 is incorporated in each magnetic core 54. Each coil 56 is manufactured by the manufacturing method according to the first embodiment.

  In this armature 50, a wide magnetic core 58 that increases the area facing the field element 42 is provided on the surface of each magnetic core 54 on the field element 42 side. The wide magnetic core 58 is usually mounted and integrated on the end face of the magnetic core 54 after the coil 56 is assembled in the magnetic core 54.

  A method for incorporating the coil 56 into the magnetic core 54 will be described.

  First, there is a method of winding a coil conducting wire directly around the magnetic core 54. As a result, the coil conductor can be wound tightly and densely around the magnetic core 54. Here, winding the coil conductor 12 directly around the magnetic core 54 means to eliminate the method of winding the coil conductor 12 in a place not around the magnetic core 54, and accordingly, an insulator is provided around the magnetic core 54. Including the case where the coil conductor is directly wound around it.

  However, as described above, in a configuration including a plurality of coils 56, particularly in a configuration including a plurality of coils 56 close to each other in an annular shape, it is necessary to perform winding using a narrow space between the magnetic cores 54. Because there is difficulty. In particular, winding that requires accuracy such as aligned winding is difficult. Therefore, as shown in FIG. 8, at least one of the plurality of coils 56 is separated from the other coils 56, and the coil 56 is directly wound around the magnetic core 54 to manufacture the coil 56. The coil 56 may be integrated with another coil 56.

  Here, a divided body 54 a is formed by dividing a back yoke magnetic core 52 in which a plurality of magnetic cores 54 are integrated into fan-shaped portions corresponding to the respective magnetic cores 54. Then, the magnetic core 54 of the divided body 54 a is separated from the others, and a coil conductor is directly wound around the magnetic core 54 to manufacture the coil 56. Thereafter, the armature 50 is assembled by integrating the divided body 54a having the coil 56 with the other with an adhesive or the like. In FIG. 8, only one divided body 54 a having one magnetic core 54 is separated from the other, but in reality, it is divided into a plurality of divided bodies 54 a corresponding to all the magnetic cores 54, and each is divided into a coil. A conducting wire is wound to manufacture the coil 56.

  Thereby, the method of winding a coil conducting wire directly around the magnetic core 54 can be easily applied to the armature 50 having the plurality of coils 56.

  Further, it is not always necessary to wind the coil conductor directly around the magnetic core 54, and as shown in FIG. 9, after the coil conductor is wound around another winding frame 60 to produce the coil 56, 56 may be attached to the magnetic core 54. Here, as the winding frame 60, a configuration having a substantially cylindrical winding frame main body 62 having an outer peripheral surface shape corresponding to the outer peripheral surface shape of the magnetic core 54, and flanges 64 formed at both ends thereof. Is adopted.

  As a result, the coil conductors can be wound without dividing the back yoke magnetic core 52 or the like into a plurality of coils 56 and without being restricted by the nearby magnetic core 54 or other member at the location where the magnetic core 54 is disposed. The coil 56 can be manufactured by turning. Further, after the coil conductor is wound around the winding frame body 60, the winding frame body 60 may be used as an insulator and attached to the magnetic core 54 as it is.

  In addition, when winding a coil conducting wire on another winding frame body, it is good to adhere | attach the coil conducting wires wound around it on the winding form by adhere | attaching during or after winding. Thereby, the coil 56 can be removed from the winding frame body and attached to the magnetic core 54, and the proximity of the coil 56 and the magnetic core 54 and the miniaturization of the coil 56 can be achieved.

  FIG. 10 shows an example of a drawing mode of the coil conductor. Here, the one end side 112a and the other end side 112b of the coil conducting wire are drawn from the other end face 125a side (corresponding to the other end face 25a in the embodiment). Moreover, since the one end side 112a and the other end side 112b of the coil conducting wire are wound in opposite directions, they are drawn out in directions opposite to each other. In addition, although the state wound by the winding frame body 60 is shown in FIG. 10, it is the same also in the aspect in which the winding frame body 60 was abbreviate | omitted.

  With reference to FIG. 2, this drawing form is such that one end side 112a of the coil conductor is drawn to the outside after the winding portion marked with "31", and the other end side 112b of the coil conductor is "32". It can be said that it is a form pulled out after the winding part marked with "".

  In this drawing form, the coil conductor can be wound around the outermost layer, and one end side 112a and the other end side 112b of the coil conductor can be drawn out from close locations.

  Further, assuming that the axial gap type rotating machine shown in FIG. 8 has multiple poles, there are cases where the coils 56 are connected in series and connected in parallel in each phase. When connected in series, one end side end portion (winding end side end portion) of one coil 56 of a certain phase and the other end side end portion (winding start side end portion) of another coil 56 in the same phase Will be connected. Further, when connected in parallel, one end side end portion (winding end side end portion) of one coil 56 of a certain phase and one end side end portion (winding end side end portion) of another coil 56 in the same phase Are connected, and the other end side end portion (winding start side end portion) of one coil 56 of a certain phase is connected to the other end side end portion (winding start side end portion) of another coil 56 in the same phase. become.

  In particular, in the case of series connection, when one end side 112a and the other end side 112b of the coil conductor of each coil 56 are drawn out from a nearby location, one coil disposed in parallel and in the same direction on substantially the same plane. The height positions of one end side end (winding end side end) of the coil 56 and the other end side end (winding start side end) of the other coil 56 can be made substantially the same. For this reason, there is an advantage that the wiring for connecting them does not become oblique and can be shortened and made compact.

  Further, as shown in FIG. 10, the one end side 112 a and the other end side 112 b of the coil conducting wire are preferably drawn out to the outside at positions arranged on the outer peripheral side of the armature 50. This is because the coils 56 can be connected without interfering with the rotating shaft portion.

  The armature 50 may be a stator or a rotor, but is preferably a motor having a permanent magnet as a rotor. With this configuration, a high magnetic flux density can be realized by the permanent magnet, and the magnetic resistance can be lowered by the magnetic core 54, so that the energy of the permanent magnet can be sufficiently exerted to achieve high torque and high operating efficiency. is there.

It is a perspective view which shows the coil manufactured by the manufacturing method of the coil which concerns on 1st Embodiment. It is explanatory drawing which shows the winding form by the manufacturing method of a coil same as the above. It is a figure which shows one process in the manufacturing method of a coil same as the above. It is explanatory drawing which shows the other winding form of a coil conducting wire. It is a figure which shows an example of the method of winding a coil conducting wire. It is a figure which shows the other example of the method of winding a coil conducting wire. It is a disassembled perspective view which shows the axial gap type rotary machine which concerns on 2nd Embodiment. It is a perspective view which shows the state which isolate | separated at least 1 of the some coils from the other coil. It is a perspective view which shows the winding frame around which a coil conducting wire is wound. It is a perspective view which shows an example of the drawing | extracting aspect of a coil conducting wire.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coil 12 Coil conducting wire 14a 1st winding part 14b 2nd winding part 16 Coil winding part 20 Magnetic core 24a One end surface 25a The other end surface 28 Axis 30 First nozzle 32 Second nozzle 36 Connection part 50 Armature 54 Magnetic core 54a Divided body 56 Coil 60 Winding frame body 125a End face

Claims (12)

A method for producing a coil (10, 56) in which a coil conductor (12) is wound around a predetermined axis (28) between a pair of opposed end faces (25a, 25b) having a predetermined width,
(A) Align one end side of the coil conducting wire (12) from one end face (25a) to the other end face (25b), from the other end face (25b) to the front leaving a margin width. A step of winding into a shape,
(B) The other end side of the coil conducting wire (12) is between the winding portion on one end side of the coil conducting wire (12) wound in the step (a) and the other end surface (25b). Winding process;
A method for manufacturing a coil comprising: A method of manufacturing a coil (10, 56) in which a coil conductor (12) is wound around a predetermined axis (25) between a pair of opposed end faces (25a, 25b) having a predetermined width,
(A) Align one end side of the coil conducting wire (12) from one end face (25a) to the other end face (25b), from the other end face (25b) to the front leaving a margin width. A step of winding into a shape,
(B-1) Winding the other end side of the coil conducting wire (12) between the winding portion on one end side of the coil conducting wire (12) wound in the step (a) and the other end face. And a step of winding the outer peripheral side as well,
(C) One end side of the coil conducting wire (12) is arranged on the outer peripheral side of the winding portion on one end side of the coil conducting wire (12) wound in the step (a), and in the step (b-1). A step of winding the coiled conductor wire (12) wound in an aligned manner from the wound part on the other end side toward the one end surface;
A method for manufacturing a coil comprising: A method for manufacturing a coil (10, 56) according to claim 1 or 2,
A method for manufacturing a coil, wherein the coil conductor (12) is wound directly around a magnetic core (20, 54). A method for manufacturing an armature (50) comprising a plurality of coils (56) manufactured by the method for manufacturing a coil according to claim 3,
An electric machine in which at least one of the plurality of coils (56) is wound around the coil conductor in a state of being separated from another coil (56) and then combined with the other coil (56) to be integrated. Child manufacturing method. A method of manufacturing a coil according to claim 1 or claim 2,
A coil manufacturing method in which the coil conductor is wound around a winding frame (60) different from the magnetic core (54) and then attached to the magnetic core (54). A method of manufacturing a coil according to claim 5,
The method of manufacturing a coil, wherein the winding body (60) is attached to the magnetic core (56) together with the coil (54) as an insulator. A method of manufacturing a coil according to claim 5,
The manufacturing method of a coil (56) which adhere | attaches the said coil conducting wire wound by the said winding frame body during the winding to the said winding frame body, or after winding. A method of manufacturing a coil according to claim 5,
A self-bonding wire is used as the coil conducting wire, and the coil conducting wires wound around the winding frame body are bonded to each other during or after being wound around the winding frame body. Production method. A method for manufacturing a coil according to any one of claims 1 to 3, and 5 to 8.
One end of the coil conductor (12) is rotated by turning the first nozzle (30) around the predetermined axis (28) while supplying one end of the coil conductor (12) from the first nozzle (30). Winding the side,
By rotating the second nozzle (32) about the predetermined axis (28) while supplying the other end side of the coil conductor (12) from the second nozzle (32), the coil conductor (12) A coil manufacturing method in which the other end is wound. A method for manufacturing a coil according to any one of claims 1 to 3, and 5 to 8.
The other end of the coil conducting wire (12) is fixed by fixing the other end of the coil conducting wire to the connecting portion (36) and turning the connecting portion (36) about the predetermined axis (28). Wind the end of the side,
While the one end side of the coil conducting wire (12) is supplied from the first nozzle (30), the first nozzle (30) is turned around the predetermined axis (28) or the object to be wound ( The manufacturing method of the coil which winds the one end side of the said coil conducting wire (12) by rotating 20). A method for manufacturing a coil according to any one of claims 1 to 3, and 5 to 10.
The manufacturing method of the coil by which the one end side (112a) of the said coil conducting wire and the other end side (112b) of the said coil conducting wire were pulled out from the winding part from the said other end surface (125a). A coil in which a coil conductor (12) is wound around a predetermined axis (28) between a pair of opposed end faces (24a, 24b) having a predetermined width,
The coil conductor (12) is
A first winding portion wound in an aligned manner over a plurality of layers from one end face (24a) to the other end face (25a) from the other end face (25a) to the front leaving a margin. (14a),
A second winding portion (14b) wound in a plurality of layers along the other end face (25a);
With
In at least one cross section along the predetermined axis (28), at least one position of the cross section of the coil conductor (12) constituting the second winding portion (24b) is an outer layer. The coil arrange | positioned in the position which overlaps inside rather than the cross-sectional position of the said coil conducting wire (12) which comprises the said 1st winding part (14a).

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