JP2004180367A - Flat air core coil and its manufacturing method - Google Patents

Flat air core coil and its manufacturing method Download PDF

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Publication number
JP2004180367A
JP2004180367A JP2002340933A JP2002340933A JP2004180367A JP 2004180367 A JP2004180367 A JP 2004180367A JP 2002340933 A JP2002340933 A JP 2002340933A JP 2002340933 A JP2002340933 A JP 2002340933A JP 2004180367 A JP2004180367 A JP 2004180367A
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Prior art keywords
coil
flat
winding
wound
flat air
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JP2004180367A5 (en
JP4310999B2 (en
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Tatsuo Abe
達雄 安部
Junichi Yasukawa
順一 安川
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Yaskawa Electric Corp
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Yaskawa Electric Corp
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Priority to JP2002340933A priority Critical patent/JP4310999B2/en
Priority to PCT/JP2003/014598 priority patent/WO2004049546A1/en
Priority to TW092132790A priority patent/TWI237939B/en
Publication of JP2004180367A publication Critical patent/JP2004180367A/en
Publication of JP2004180367A5 publication Critical patent/JP2004180367A5/ja
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435—Wound windings
    • H02K15/0442—Loop windings
    • H02K15/045—Form wound coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/47—Air-gap windings, i.e. iron-free windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/02—Fixed inductances of the signal type  without magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Windings For Motors And Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flat air core coil improved in the electric insulation of the coil and prevented in deformation caused by the secondary heating of the coil. <P>SOLUTION: The flat air core coil comprises a first coil 8 wound with a flat copper wire and a second coil 9 wound with the flat copper wire in the reverse direction relative to the first coil 8. In the flat air core coil, the first coil 8 and the second coil 9 are electrically connected, and an insulating film 18 is interposed between the first coil and the second coil. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、工作機械や搬送装置に使用する産業用直動機に関し、特にリニアモータ電機子の成形コイルとしての２個の平形空芯コイルろ並置して成る２層扁平形空芯コイルとその製造方法に関する。
【０００２】
【従来の技術】
図５はリニアモータの構成を示す正面断面図である。
図５において、１はリニアモータの電機子、２はリニアモータの固定子、３は成形コイル、４は永久磁石、６は芯金、７はエポキシ樹脂である。
図から判るように、リニアモータの固定子２の対向する永久磁石４の空隙間をリニアモータの電機子１は左右に移動するもので、この電機子１は芯金６の上下面に成形コイル３を接着し、エポキシ樹脂７でモールドして成るものである。
その成形コイル３は、小形軽量化をはかり、コイルの高占積率化のため、扁平形の第１コイル８と扁平形の第２コイル９とを併置して２層扁平形空芯コイルとなっている。そこで平角銅線の一層目コイルとこれと逆方向に巻回され並置される二層目コイルから成る平角線二重巻きの巻線方法はこれまでいくつか知られている（例えば、特許文献１〜３参照）。
【０００３】
【特許文献１】
特開昭６２−２６０５３５号公報
【特許文献２】
特開平５−２４３０３６号公報
【特許文献３】
特開平８−３１７６１０号公報
【０００４】
【発明が解決しようとする課題】
図６はその扁平形の第１コイル８と扁平形の第２コイル９とを並置して成る従来の２層扁平形空芯コイルの斜視図である。
図６において、３は成形コイル、８は第１コイル、９は第２コイル、１０は加熱形自己融着平角銅線、１２はコイル空芯部である。
従来の２層扁平形空芯コイルでは、図６の成形コイル３を加熱形自己融着平角銅線１０で製作する時、第１コイル８と第２コイル９のコイル側面同士が接触して互いに傷が付くことが起こった。
図７はコイル側面同士が接触した場合の状態を説明する図で、従来の加熱による二次加工後のコイルの変形を示している。（ａ）は変形したコイルの斜視図、（ｂ）はコイルの側面断面図、（ｃ）は（ｂ）のコイルの一部を断面し誇張して示す拡大図である。
図７（ｂ）の第１コイル８とこれに隣接する第２コイル９のコイル側面１１同士がに図７（ｃ）のように傷が付くと、絶縁皮膜が剥離し、第１コイル８と第２コイル９とが電気的に短絡（ショート）した。
また、リニアモータ電機子１の製作時、エポキシ樹脂７で全体をモールドすると二次加熱で加熱形自己融着平角銅線１０の接着力が弱まり、図６のような矩形空芯部付き成形コイル３が図７（ａ）のように膨張変形し、外側膨張変形部２１と内側膨張変形部２２が発生してこのときのストレスでエポキシ樹脂７（図５）のモールドにクラックが発生した。
そこで、本発明は上記欠点を解決するためになされたもので、コイルの電気絶縁性の向上と加熱による熱変形防止を図り、したがって第１コイルと第２コイルとがショートしない、またリニアモータ電機子の製作時の二次加熱でも加熱形自己融着平角銅線の接着力が弱まらない、エポキシ樹脂７のモールドにクラックが発生ない扁平形空芯コイルとその製造方法を提供することを目的としている。
【０００５】
【課題を解決するための手段】
上記問題を解決するために、請求項１記載の扁平形空芯コイルの発明は、平角銅線の巻回された第１コイルと該第１コイルと逆方向に平角銅線の巻回された第２コイルとを備え、前記第１コイルと前記第２コイルが電気的に接続する扁平形空芯コイルにおいて、前記第１コイルと前記第２コイルの間に絶縁フィルムを介挿したことを特徴とする。
このような構成とすることにより、前記第１コイルと前記第２コイルの間に絶縁フィルムを介挿したので、互いの接触による損傷が無くなり、第１コイルと第２コイルとがショートしなくなる。したがって、エポキシ樹脂のモールドにクラックも発生しなくなる。
請求項２記載の扁平形空芯コイルの製造方法の発明は、平角銅線の巻回された第１コイルと該第１コイルと逆方向に平角銅線の巻回された第２コイルとを備え、該第１コイルと該第２コイルとを電気的に接続した扁平形空芯コイルにおいて、前記第１コイルと前記第２コイルを同一材料で成る平角銅線を連続的にかつ前記第１コイルと前記第２コイルとの間に空隙を開けて巻き、その空隙間に絶縁フィルムを介挿したことを特徴とする。
このような構成とすることにより、第１コイルと第２コイルとがショートしない、エポキシ樹脂のモールドにクラックも発生しない扁平形空芯コイルを簡単に製造することができるようになる。
請求項３記載の発明は、請求項２記載の扁平形空芯コイルの製造方法において、前記絶縁フィルムの外周に熱硬化性接着剤を塗布したことを特徴とする。
このような構成とすることにより、リニアモータ電機子の製作時の二次加熱でも加熱形自己融着平角銅線の接着力が弱まらない扁平形空芯コイルを簡単に製造することができるようになる。
【０００６】
【発明の実施の形態】
以下、本発明の実施の形態について図１〜図４に基づいて詳細に説明する。
図１は平角線二重巻きコイルの巻線例を説明する図で、巻き始め（ａ）から巻き終わり（ｄ）までを示す図であり、図２は本発明に係る平角線二重巻きコイルの製造方法を示す説明図であり、図３は図２の方法によって得られた平角線二重巻きコイルを示す図で、（ａ）はコイルの斜視図、（ｂ）はコイルの一部を断面し、誇張して示す拡大図であり、図４は本発明に用いられる電気絶縁紙の一実施例を示す図で、（ａ）は正面図、（ｂ）は側面断面図である。
図１において、５０はこの巻き取り装置の全体、５１は巻線を巻き取る巻線治具で、回転軸５１ａを中心に角速度ω１で所定方向（図では反時計方向）に自転している。５２は遊星リール、５２ａは巻線治具５１の回転軸５１ａを中心に角速度２ω１で公転する遊星軸で、ここに遊星リール５２が回転可能に取り付けられている。５３は平角線を巻回して成るドラムで、その回転軸５３ａを中心に自転する。５４は平角線である。
【０００７】
次に、この平角線二重巻きの巻き方を説明する。
巻き始めの（ａ）において、巻線に必要とする平角線５４の長さの半分をドラム５３から遊星リール５２に巻き取っておく。もう他方の平角線は切断せずにドラム５３に残したまま巻線治具５１の下方を通過させる。そして平角線５４にテンションを掛けながら、巻線治具５１を回転軸５１ａを中心に角速度ω１で反時計方向に回転開始する。これと同時に遊星リール５２を角速度２ω１で反時計方向に公転させる。
図（ｂ）は図（ａ）の状態から巻線治具５１を９０度、遊星リール５２を１８０度回転させた状態を示している。遊星リール５２が巻線治具５１の角速度の２倍の角速度で公転するため、巻線治具５１の上に１層の巻線５６が半周分形成されている。
図（ｃ）は図（ｂ）の状態からさらに巻線治具５１を９０度、遊星リール５２を１８０度回転させた状態を示している。遊星リール５２が巻線治具５１の角速度の２倍の角速度で公転するため、巻線治具５１の上に１層の巻線５６が１周分形成されている。
図（ｄ）は図（ｃ）の状態からさらに巻線治具５１を多数回自転、遊星リール５２を同数回公転させた後の終了状態を示している。遊星リール５２が巻線治具５１の角速度の２倍の角速度で公転するため、巻線治具５１の上に多数回巻回された平角線巻線５６と、同じく多数回巻回された平角線巻線５７が形成されている。この後、巻線治具５１を抜き取れば平角線による空芯の二重巻線（アルファ巻きとも言う。）ができあがる。
【０００８】
なお、図１のようにコイルを巻いている間、図２（ａ）のように、加熱形自己融着平角銅線９を加熱ヒータ１６で加熱しながら、接着してゆくとバラケ防止をするのでよい。
その際、本発明により、図２（ａ）の第１の平角線巻線８と第２の平角線巻線９との間に０．３〜０．５ｍｍのコイル間スキマ５を設けているのが特徴である。
そして、平角線巻線５６と平角線巻線５７との間に作られたコイル間スキマ５に図２（ｂ）のように半割り電気絶縁紙１７を上下より挿入し、第１コイル８を図の矢印Ａ方向に、また第２コイル９を図の矢印Ｂ方向にスライドさせて、スキマを埋める。
次に、巻線治具１３をコイルより抜き取ると、図３（ａ）および（ｂ）のような成形コイル３が完成する。
図３において、３は成形コイル、８は第１コイル、９は第２コイル、１７は半割電気絶縁紙、１８は絶縁フィルム、１９は熱硬化性接着剤である。
成形コイル３は第１コイル８とこれとスキマを空けて並置される第２コイル９と、このスキマに挿入される絶縁フィルム１８から成る半割電気絶縁紙１７と、半割電気絶縁紙１７と第１および第２コイルの間を接着する熱硬化性接着剤１９とから構成されている。
図４は本発明に用いられる半割電気絶縁紙１７の一実施例を示す図で、（ａ）は正面図、（ｂ）は側面断面図である。図において、１７はコ字状をした半割電気絶縁紙、１８は半割電気絶縁紙１７を構成する絶縁フィルム、１９は熱硬化性接着剤、２０はコ字状の半割電気絶縁紙１７を２個突き合わせた半割部（突き合わせ部）である。
本発明の製造方法によれば、平角銅線第１コイル８とこれと逆方向に巻き廻された第２コイル９とをスキマを置いて並置し、電気的接続する２層扁平空芯コイルの第１コイル８と第２コイル９のスキマに、絶縁フィルム１８の両面に熱硬化性接着剤１９を塗布した空芯半割りの電気絶縁紙１７を挿入したので、図４（ｂ）の絶縁フィルム１８が電気絶縁性を高めると同時に熱硬化性接着剤１９がコイルの加熱による変形を防止することとなる。
【０００９】
【発明の効果】
以上述べたように、本発明は、第１コイルと第２コイルのスキマに、熱硬化性接着剤を両面に塗布した絶縁フィルムを挿入することにより、コイルの電気絶縁性が向上し、コイルの二次加熱による変形を防止する。
【図面の簡単な説明】
【図１】平角線二重巻きの１例を説明する図で、巻き始め（ａ）から巻き終わり（ｄ）までを示す図である。
【図２】本発明の平角線二重巻きコイルの製造方法を示す斜視図で、（ａ）はスキマを空けて巻回中の斜視図、（ｂ）はそのスキマに本発明により半割電気絶縁紙を挿入する途中の斜視図である。
【図３】本発明の実施の形態に係るコイルを示す図で、（ａ）はコイルの斜視図、（ｂ）はコイルの一部を断面し、誇張して示す拡大図である。
【図４】本発明の電気絶縁紙の一実施例を示す図で、（ａ）は正面図、（ｂ）は側面断面図。
【図５】本発明が対象とするリニアモータの構成を示す正面断面図。
【図６】従来コイルの斜視図である。
【図７】従来製法の加熱による二次加工後の変形コイルを示す図で、（ａ）は斜視図、（ｂ）は側面断面図、（ｃ）はコイルの一部を断面し誇張して示す拡大図である。
【符号の説明】
１ リニアモータ電機子
２ リニアモータ固定子
３ 成形コイル
４ 永久磁石
５ コイル間スキマ
６ 芯金
７ エポキシ樹脂
８ 第１コイル
９ 第２コイル
１０ 加熱形自己融着平角銅線
１１ コイル側面
１２ コイル空芯部
１３ 形枠
１４ 第１コイルボビン
１５ 第２コイルボビン
１６ 加熱ヒータ
１７ 半割電気絶縁紙
１８ 絶縁フィルム
１９ 熱硬化性接着剤
２０ 半割部
２１ 内側膨張変形部
２２ 外側膨張変形部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an industrial linear motion machine used for a machine tool and a transfer device, and more particularly to a two-layer flat air core coil formed by juxtaposing two flat air core coils as a forming coil of a linear motor armature, and manufacturing the same. About the method.
[0002]
[Prior art]
FIG. 5 is a front sectional view showing the configuration of the linear motor.
In FIG. 5, reference numeral 1 denotes an armature of a linear motor, 2 denotes a stator of the linear motor, 3 denotes a molded coil, 4 denotes a permanent magnet, 6 denotes a metal core, and 7 denotes an epoxy resin.
As can be seen from the figure, the armature 1 of the linear motor moves left and right through the gap between the opposing permanent magnets 4 of the stator 2 of the linear motor. 3 is bonded and molded with an epoxy resin 7.
The molded coil 3 has a flat first coil 8 and a flat second coil 9 arranged side by side to form a two-layer flat air core coil in order to reduce the size and weight and to increase the space factor of the coil. Has become. Therefore, there have been known several winding methods of a flat wire double winding comprising a first layer coil of a flat copper wire and a second layer coil wound in the opposite direction and juxtaposed (for example, Patent Document 1). 3).
[0003]
[Patent Document 1]
JP-A-62-260535 [Patent Document 2]
JP-A-5-243036 [Patent Document 3]
Japanese Patent Application Laid-Open No. 8-317610
[Problems to be solved by the invention]
FIG. 6 is a perspective view of a conventional two-layer flat air-core coil in which the flat first coil 8 and the flat second coil 9 are juxtaposed.
In FIG. 6, 3 is a formed coil, 8 is a first coil, 9 is a second coil, 10 is a heating type self-fusing flat copper wire, and 12 is a coil core.
In the conventional two-layer flat air-core coil, when the molded coil 3 of FIG. 6 is manufactured from a heated type self-fusing rectangular copper wire 10, the coil side surfaces of the first coil 8 and the second coil 9 come into contact with each other. Scratching happened.
FIG. 7 is a view for explaining a state where the coil side surfaces are in contact with each other, and shows a deformation of the coil after the secondary processing by the conventional heating. (A) is a perspective view of a deformed coil, (b) is a side sectional view of the coil, and (c) is an enlarged view showing a part of the coil of (b) in a cross-sectional view.
When the coil side surfaces 11 of the first coil 8 of FIG. 7B and the second coil 9 adjacent thereto are scratched as shown in FIG. 7C, the insulating film is peeled off, and the first coil 8 The second coil 9 was electrically short-circuited (short-circuited).
In addition, when the linear motor armature 1 is manufactured, if the entire body is molded with the epoxy resin 7, the adhesive force of the heated self-fusing rectangular copper wire 10 is weakened by the secondary heating, and a molded coil having a rectangular hollow core as shown in FIG. 7 was expanded and deformed as shown in FIG. 7A, an outer expanded deformed portion 21 and an inner expanded deformed portion 22 were generated, and cracks occurred in the mold of the epoxy resin 7 (FIG. 5) due to the stress at this time.
SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned drawbacks, and aims at improving the electrical insulation of the coil and preventing thermal deformation due to heating, so that the first coil and the second coil are not short-circuited. To provide a flat air-core coil in which the adhesiveness of a heated self-fusing rectangular copper wire is not weakened even by secondary heating at the time of manufacture of a child and cracks do not occur in a mold of an epoxy resin 7, and a method of manufacturing the same. The purpose is.
[0005]
[Means for Solving the Problems]
In order to solve the above problem, the flat air-core coil according to the first aspect of the present invention includes a first coil wound with a flat copper wire and a flat copper wire wound in a direction opposite to the first coil. A flat air-core coil, comprising a second coil, wherein the first coil and the second coil are electrically connected, wherein an insulating film is interposed between the first coil and the second coil. And
With such a configuration, since the insulating film is interposed between the first coil and the second coil, damage due to mutual contact is eliminated, and the first coil and the second coil are not short-circuited. Therefore, cracks do not occur in the epoxy resin mold.
According to a second aspect of the present invention, there is provided a method for manufacturing a flat air-core coil, comprising: a first coil wound with a flat copper wire; and a second coil wound with a flat copper wire in a direction opposite to the first coil. A flat air-core coil in which the first coil and the second coil are electrically connected, wherein the first coil and the second coil are formed by continuously forming a rectangular copper wire made of the same material into the first coil. A gap is opened between the coil and the second coil, and the coil is wound, and an insulating film is inserted into the gap.
With such a configuration, it is possible to easily manufacture a flat air-core coil in which the first coil and the second coil do not short-circuit and cracks do not occur in the epoxy resin mold.
According to a third aspect of the present invention, in the method for manufacturing a flat air-core coil according to the second aspect, a thermosetting adhesive is applied to an outer periphery of the insulating film.
With this configuration, it is possible to easily manufacture a flat air-core coil in which the adhesive force of the heated self-fusing rectangular copper wire is not weakened even in the secondary heating at the time of manufacturing the linear motor armature. Become like
[0006]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to FIGS.
FIG. 1 is a diagram for explaining an example of winding of a rectangular wire double-wound coil, and is a diagram showing from winding start (a) to winding end (d). FIG. 2 is a rectangular wire double-wound coil according to the present invention. FIG. 3 is a diagram showing a flat wire double-wound coil obtained by the method of FIG. 2, (a) is a perspective view of the coil, and (b) is a part of the coil. FIG. 4 is an enlarged view showing a section and an exaggerated view. FIG. 4 is a view showing one embodiment of the electric insulating paper used in the present invention, in which (a) is a front view and (b) is a side sectional view.
In FIG. 1, reference numeral 50 denotes the entire winding device, and reference numeral 51 denotes a winding jig for winding the winding, which rotates in a predetermined direction (counterclockwise in the figure) at an angular velocity ω1 about a rotation shaft 51a. Reference numeral 52 denotes a planetary reel, and reference numeral 52a denotes a planetary shaft which revolves around an axis of rotation 51a of the winding jig 51 at an angular velocity of 2ω1. The planetary reel 52 is rotatably mounted here. Reference numeral 53 denotes a drum formed by winding a rectangular wire, and rotates around its rotation shaft 53a. 54 is a flat wire.
[0007]
Next, the winding method of the flat wire double winding will be described.
In (a) at the beginning of winding, half of the length of the flat wire 54 required for winding is wound from the drum 53 onto the planetary reel 52. The other flat wire is passed under the winding jig 51 without being cut and left on the drum 53. Then, while applying tension to the flat wire 54, the winding jig 51 starts to rotate counterclockwise around the rotation shaft 51a at an angular velocity ω1. At the same time, the planetary reel 52 revolves counterclockwise at an angular velocity of 2ω1.
FIG. 2B shows a state in which the winding jig 51 is rotated by 90 degrees and the planetary reel 52 is rotated by 180 degrees from the state of FIG. Since the planetary reel 52 revolves at twice the angular velocity of the winding jig 51, a single-layer winding 56 is formed on the winding jig 51 for a half turn.
FIG. (C) shows a state in which the winding jig 51 is further rotated by 90 degrees and the planetary reel 52 is rotated by 180 degrees from the state of FIG. Since the planetary reel 52 revolves at twice the angular velocity of the winding jig 51, a single-layer winding 56 is formed on the winding jig 51 for one round.
FIG. 6D shows the end state after the winding jig 51 has rotated many times and the planetary reel 52 has revolved the same number of times from the state of FIG. Since the planetary reel 52 revolves at an angular velocity twice the angular velocity of the winding jig 51, a flat wire winding 56 wound many times on the winding jig 51 and a flat angle wound many times on the winding jig 51 as well. A wire winding 57 is formed. Thereafter, if the winding jig 51 is removed, a double-core air-core winding (also referred to as an alpha winding) using a flat wire is completed.
[0008]
While the coil is wound as shown in FIG. 1, the heating type self-fusing rectangular copper wire 9 is heated by the heater 16 as shown in FIG. So good.
In this case, according to the present invention, a gap 5 between the coils of 0.3 to 0.5 mm is provided between the first rectangular wire winding 8 and the second rectangular wire winding 9 in FIG. It is characteristic.
Then, as shown in FIG. 2 (b), a half-split electric insulating paper 17 is inserted from above and below into the inter-coil gap 5 formed between the rectangular wire winding 56 and the rectangular wire winding 57, and the first coil 8 is inserted. The gap is buried by sliding the second coil 9 in the direction of arrow B in the figure and the direction of arrow B in the figure.
Next, when the winding jig 13 is removed from the coil, the formed coil 3 as shown in FIGS. 3A and 3B is completed.
In FIG. 3, 3 is a molded coil, 8 is a first coil, 9 is a second coil, 17 is a half electric insulating paper, 18 is an insulating film, and 19 is a thermosetting adhesive.
The formed coil 3 includes a first coil 8, a second coil 9 juxtaposed with the first coil 8, a half electric insulating paper 17 comprising an insulating film 18 inserted into the gap, and a half electric insulating paper 17. And a thermosetting adhesive 19 for bonding between the first and second coils.
4A and 4B are views showing one embodiment of the half electric insulating paper 17 used in the present invention, wherein FIG. 4A is a front view, and FIG. 4B is a side sectional view. In the figure, 17 is a U-shaped half electric insulating paper, 18 is an insulating film constituting the half electric insulating paper 17, 19 is a thermosetting adhesive, and 20 is a U-shaped half electric insulating paper 17. Are halved portions (butted portions).
According to the manufacturing method of the present invention, the two-layer flat air-core coil in which the rectangular copper wire first coil 8 and the second coil 9 wound in the opposite direction are juxtaposed and placed side by side and electrically connected to each other. Since the air-core half-insulated electric insulating paper 17 coated with the thermosetting adhesive 19 on both sides of the insulating film 18 was inserted into the gap between the first coil 8 and the second coil 9, the insulating film shown in FIG. At the same time, the thermosetting adhesive 19 prevents deformation due to heating of the coil.
[0009]
【The invention's effect】
As described above, the present invention improves the electrical insulation of the coil by inserting the insulating film coated with the thermosetting adhesive on both sides into the gap between the first coil and the second coil, thereby improving the electrical insulation of the coil. Prevents deformation due to secondary heating.
[Brief description of the drawings]
FIG. 1 is a view for explaining an example of double winding of a flat wire, and is a view showing a state from a winding start (a) to a winding end (d).
FIGS. 2A and 2B are perspective views showing a method for manufacturing a rectangular wire double-wound coil according to the present invention, wherein FIG. 2A is a perspective view showing a gap in which winding is performed, and FIG. It is a perspective view in the middle of inserting insulating paper.
3A and 3B are views showing a coil according to an embodiment of the present invention, wherein FIG. 3A is a perspective view of the coil, and FIG. 3B is an enlarged view showing a part of the coil in cross section.
FIG. 4 is a view showing one embodiment of the electric insulating paper of the present invention, wherein (a) is a front view and (b) is a side sectional view.
FIG. 5 is a front sectional view showing the configuration of a linear motor to which the present invention is applied.
FIG. 6 is a perspective view of a conventional coil.
7A and 7B are diagrams showing a deformed coil after secondary processing by heating according to a conventional manufacturing method, wherein FIG. 7A is a perspective view, FIG. 7B is a side sectional view, and FIG. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Linear motor armature 2 Linear motor stator 3 Molded coil 4 Permanent magnet 5 Clearance between coils 6 Core metal 7 Epoxy resin 8 First coil 9 Second coil 10 Heated self-fusing flat copper wire 11 Coil side surface 12 Coil air core Part 13 Form 14 First coil bobbin 15 Second coil bobbin 16 Heater 17 Half electric insulating paper 18 Insulating film 19 Thermosetting adhesive 20 Half part 21 Inner expanding deforming part 22 Outer expanding deforming part

Claims (3)

平角銅線の巻回された第１コイルと該第１コイルと逆方向に平角銅線の巻回された第２コイルとを備え、前記第１コイルと前記第２コイルが電気的に接続する扁平形空芯コイルにおいて、
前記第１コイルと前記第２コイルの間に絶縁フィルムを介挿したことを特徴とする扁平形空芯コイル。A first coil wound with a rectangular copper wire; and a second coil wound with a rectangular copper wire in a direction opposite to the first coil, wherein the first coil and the second coil are electrically connected. In a flat air core coil,
A flat air core coil, wherein an insulating film is interposed between the first coil and the second coil. 平角銅線の巻回された第１コイルと該第１コイルと逆方向に平角銅線の巻回された第２コイルとを備え、該第１コイルと該第２コイルとを電気的に接続した扁平形空芯コイルにおいて、
前記第１コイルと前記第２コイルを同一材料で成る平角銅線を連続的にかつ前記第１コイルと前記第２コイルとの間に空隙を開けて巻き、その空隙間に絶縁フィルムを介挿したことを特徴とする扁平形空芯コイルの製造方法。A first coil wound with a rectangular copper wire; and a second coil wound with a rectangular copper wire in a direction opposite to the first coil, and the first coil and the second coil are electrically connected. Flat air core coil
The first coil and the second coil are continuously wound with a rectangular copper wire made of the same material with a gap between the first coil and the second coil, and an insulating film is inserted into the gap. A method of manufacturing a flat air core coil. 前記絶縁フィルムの外周に熱硬化性接着剤を塗布したことを特徴とする請求項２記載の扁平形空芯コイルの製造方法。The method for manufacturing a flat air-core coil according to claim 2, wherein a thermosetting adhesive is applied to an outer periphery of the insulating film.
JP2002340933A 2002-11-25 2002-11-25 Flat air core coil, manufacturing method thereof, and linear motor using the same Expired - Fee Related JP4310999B2 (en)

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JP2008043077A (en) * 2006-08-07 2008-02-21 Nidec Sankyo Corp Motor
WO2009025076A1 (en) * 2007-08-17 2009-02-26 Ntn Corporation Magnetic bearing device integral with motor
DE102013011347A1 (en) * 2013-07-08 2015-01-08 Thomas Magnete Gmbh Magnetic coil and method for its production
NL2011753C2 (en) * 2013-11-07 2015-05-11 Tecnotion B V Multi-layer flat wire coil.
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US10163565B2 (en) 2013-11-07 2018-12-25 Tecnotion B.V. Method for winding a multi-layer flat wire coil

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