JP4500654B2 - Method for manufacturing irregular cross-section coil - Google Patents

Method for manufacturing irregular cross-section coil Download PDF

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JP4500654B2
JP4500654B2 JP2004340283A JP2004340283A JP4500654B2 JP 4500654 B2 JP4500654 B2 JP 4500654B2 JP 2004340283 A JP2004340283 A JP 2004340283A JP 2004340283 A JP2004340283 A JP 2004340283A JP 4500654 B2 JP4500654 B2 JP 4500654B2
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cross
coil
section
manufacturing
irregular cross
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JP2006157989A (en
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剛 有吉
貴雄 前田
康浩 遠藤
良治 水谷
健司 原田
寛史 井下
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Sumitomo Electric Industries Ltd
Toyota Motor Corp
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Toyota Motor Corp
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

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Description

本発明は、加圧成形により異形断面コイルを製造する技術に関する。   The present invention relates to a technique for manufacturing a modified cross-section coil by pressure molding.

ハイブリッド自動車や電気自動車等のためのモータにおいては、その高効率化及び高出力化が要望されている。一般に、モータの高効率化及び高出力化のためには、駆動熱の放熱効果を高めるとともに、コイルの占積率（コイルの配置空間の断面における導線面積の比率）を向上させることが有効であるとされている。   In motors for hybrid vehicles and electric vehicles, there is a demand for higher efficiency and higher output. In general, in order to increase the efficiency and output of a motor, it is effective to increase the heat dissipation effect of the drive heat and to improve the coil space factor (the ratio of the conductor area in the section of the coil arrangement space). It is said that there is.

従来、モータの放熱効果を高めるために、導線が積層されずに単層に巻かれた構造のコイルが提案されている。また、このようなコイルの占積率を向上させるために、異形断面形状のコイル（以下、「異形断面コイル」という。）が提案されている。この異形断面コイルは、例えば、モータの回転軸側から径方向に沿って周縁側に向かうほど、導線の断面の厚み（モータの径方向に沿った幅）が小となるかわりに、異形断面コイルの幅（モータの径方向に直交する方向の幅）が大となる構造を有している（例えば、特許文献１参照。）。   Conventionally, in order to enhance the heat dissipation effect of a motor, a coil having a structure in which a conductive wire is wound in a single layer without being laminated has been proposed. In addition, in order to improve the space factor of such a coil, a coil having an irregular cross-sectional shape (hereinafter referred to as “an irregular cross-sectional coil”) has been proposed. For example, instead of the thickness of the cross section of the conducting wire (width along the radial direction of the motor) becoming smaller from the rotation axis side of the motor toward the peripheral side along the radial direction, (The width in the direction orthogonal to the radial direction of the motor) is large (see, for example, Patent Document 1).

特開２００４−８０８６１号公報JP 2004-80861 A

ところで、上述した異形断面コイルのための導線を圧延により製造すると仮定した場合、コイルの部分に応じて導線の断面形状を漸次に変更するという圧延が必要である。したがって、この場合は、圧延に際して緻密な制御が要求され、異形断面コイルの製造コストが嵩むおそれがある。   By the way, when it is assumed that the conducting wire for the above-described irregular cross-section coil is manufactured by rolling, rolling is required to gradually change the cross-sectional shape of the conducting wire in accordance with the coil portion. Therefore, in this case, precise control is required at the time of rolling, which may increase the manufacturing cost of the irregularly shaped cross-section coil.

このため、異形断面コイルを低コストかつ簡易に製造可能なように、一定の断面形状を有する導線を型芯に螺旋状に巻いて中間コイル体を形成し、その中間コイル体を軸方向の端部の双方から加圧（プレス加工）することにより成形型のキャビティに応じた異形断面形状に成形するという製造手法が検討されている。   Therefore, an intermediate coil body is formed by spirally winding a conductive wire having a constant cross-sectional shape around a mold core so that a modified cross-section coil can be manufactured at low cost and easily. A manufacturing method is being studied in which molding is performed into a deformed cross-sectional shape corresponding to a cavity of a mold by pressurizing (pressing) both sides.

一方で、異形断面コイルを形成する導線は、導線が延びる方向に沿って一定割合で漸次に変形することがモータの効率上望ましい。しかしながら、通常、単に導線を螺旋状に巻いただけの中間コイル体の軸方向の端部は段差を有することから、上記プレス加工による製造では、その段差により圧力変位が生じてコイルの軸方向の端部付近において導線の無秩序な変形が生じてしまう。   On the other hand, it is desirable for the efficiency of the motor that the conducting wire forming the irregular cross-sectional coil is gradually deformed at a constant rate along the direction in which the conducting wire extends. However, since the end in the axial direction of the intermediate coil body, which is merely a spiral winding of the conducting wire, usually has a step, in the manufacture by the above press working, pressure displacement occurs due to the step and the end in the axial direction of the coil. In the vicinity of the part, random deformation of the conductive wire occurs.

本発明は、上記課題に鑑みてなされたものであり、加圧成形によるコイルの端部付近における線材の無秩序な変形を防止できるコイルの製造方法を提供することを目的とする。   This invention is made | formed in view of the said subject, and it aims at providing the manufacturing method of the coil which can prevent the disorder | damage | failure deformation | transformation of the wire around the edge part of a coil by pressure molding.

上記課題を解決するため、請求項１の発明は、異形断面コイルの製造方法であって、（ａ）線材を型芯に螺旋状に巻いて中間コイル体を形成する工程と、（ｂ）前記中間コイル体の軸方向の端部を、前記軸方向に直交する平面に沿った形状に加工する工程と、（ｃ）加工された前記中間コイル体の端部を前記軸方向に沿って加圧することにより、前記中間コイル体を成形型のキャビティに応じた形状に変形させて異形断面のコイルを製造する工程と、を備えている。   In order to solve the above-mentioned problems, the invention of claim 1 is a method for manufacturing a modified cross-section coil, wherein (a) a wire is spirally wound around a mold core to form an intermediate coil body; A step of processing an end portion of the intermediate coil body in the axial direction into a shape along a plane orthogonal to the axial direction; and (c) pressurizing the end portion of the processed intermediate coil body along the axial direction. Thus, the intermediate coil body is deformed into a shape corresponding to the cavity of the molding die to produce a coil having an irregular cross section.

また、請求項２の発明は、請求項１に記載の異形断面コイルの製造方法において、（ｄ）前記工程（ｃ）の後、前記異形断面コイルの端部の前記線材において前記工程（ｂ）の加工により断面積が減少した部分を切断する工程、をさらに備えている。   The invention of claim 2 is the method of manufacturing a modified cross-section coil according to claim 1, wherein (d) after the step (c), in the wire at the end of the modified cross-section coil, the step (b) A step of cutting a portion having a reduced cross-sectional area by the processing.

また、請求項３の発明は、請求項１または２に記載の異形断面コイルの製造方法において、前記線材は一定断面形状とされ、前記型芯に均一に巻き付けられる。   According to a third aspect of the present invention, in the method for producing a modified cross-section coil according to the first or second aspect, the wire has a constant cross-sectional shape and is uniformly wound around the mold core.

また、請求項４の発明は、請求項１ないし３のいずれかに記載の異形断面コイルの製造方法において、前記成形型は段階的なキャビティを有する複数の成形型からなり、各成形型による複数回の加圧成形によって段階的な変形により所定形状の異形断面のコイルを製造する。   According to a fourth aspect of the present invention, in the method for manufacturing a deformed cross-section coil according to any one of the first to third aspects, the mold includes a plurality of molds having stepped cavities. A coil having an irregular cross section having a predetermined shape is manufactured by stepwise deformation by the pressure forming.

請求項１ないし４の発明によれば、中間コイル体の端部を軸方向に直交する平面に沿った形状に加工した後に、軸方向に沿って加圧して成形するため、製造される異形断面コイルの端部付近における線材の無秩序な変形を効果的に防止できる。   According to invention of Claim 1 thru | or 4, after processing the edge part of an intermediate | middle coil body into the shape along the plane orthogonal to an axial direction, in order to shape | mold by pressurizing along an axial direction, the unusual cross section manufactured It is possible to effectively prevent random deformation of the wire near the end of the coil.

また、特に請求項２の発明によれば、線材において平面加工工程により断面積が減少した部分を切断するため、線材において不完全な部分を排除できる。   In particular, according to the second aspect of the invention, since the portion of the wire whose cross-sectional area is reduced by the planar processing step is cut, an incomplete portion of the wire can be eliminated.

また、特に請求項３の発明によれば、一定断面形状の線材を使用するため、線材製造時における断面形状の制御が容易であり、また線材の巻き付け時においても均一に巻き付ければよく、巻き付け力の制御が容易であるため、異形断面のコイルを容易に製造できる。   In particular, according to the invention of claim 3, since a wire having a constant cross-sectional shape is used, it is easy to control the cross-sectional shape at the time of manufacturing the wire, and it is sufficient that the wire is wound evenly during winding. Since the control of the force is easy, a coil having an irregular cross section can be easily manufactured.

また、特に請求項４の発明によれば、各成形型による複数回の加圧成形によって段階的な変形により所定形状の異形断面のコイルを製造するため、安定した断面形状の異形断面コイルを製造できる。   In particular, according to the invention of claim 4, since a coil having a predetermined cross-section having a predetermined shape is manufactured by stepwise deformation by a plurality of pressure moldings by each mold, a cross-section coil having a stable cross-section is manufactured. it can.

＜１．異形断面コイルの製造＞
以下、本発明の実施形態に係る異形断面コイルの製造方法を図面を参照しつつ説明する。以下の説明において製造される異形断面コイルは、例えば、ハイブリッド自動車や電気自動車等に使用されるモータに採用され、そのモータのステータのコアに配置されるものとする。 <1. Production of irregular cross-section coil>
Hereinafter, a method for manufacturing a modified cross-section coil according to an embodiment of the present invention will be described with reference to the drawings. The deformed cross-sectional coil manufactured in the following description is employed in, for example, a motor used in a hybrid vehicle, an electric vehicle, and the like, and is disposed in a stator core of the motor.

まず、図１に示されるように、柱状の型芯１が用意され、この型芯１の外周に角形（もしくは丸形）の一定の断面形状を有する導線（線材）２９が、均一かつ単層に螺旋状に巻き付けられる。これにより、図２に示すように、型芯１の断面と同一の内部形状を有する中間コイル体２が形成される。この型芯１は、異形断面コイルの配置対象であるモータのコアと同一の断面形状を有している。したがって、中間コイル体２の内部形状は、モータのコアの断面と同一形状となる。   First, as shown in FIG. 1, a column-shaped mold core 1 is prepared, and a conductive wire (wire) 29 having a constant cross-sectional shape of square (or round) is uniformly and single-layered on the outer periphery of the mold core 1. Wound in a spiral. Thereby, as shown in FIG. 2, the intermediate coil body 2 having the same internal shape as the cross section of the mold core 1 is formed. This mold core 1 has the same cross-sectional shape as the core of the motor, which is the target for arranging the irregular cross-section coil. Therefore, the internal shape of the intermediate coil body 2 is the same shape as the cross section of the core of the motor.

次に、図３に示すように、中間コイル体２の軸方向（中間コイル体２の内部空間の中心軸ａｘが延びる方向）の２つの端部２１，２２の双方が削られ、軸方向に直交する平面に沿う形状に加工される。つまり、図２に示す状態では、中間コイル体２の軸方向の端部２１，２２には引き出し線等が存在して中間コイル体２は軸方向において段差があるが、図３に示すように、この引き出し線等が取り除かれ、中間コイル体２の端部２１，２２を形成する導線が軸方向に直交する平面に対して面で接触可能とされる。このとき、削り加工された端部２１，２２の導線は、その断面積が所定よりも減少することになる。   Next, as shown in FIG. 3, both of the two end portions 21 and 22 in the axial direction of the intermediate coil body 2 (the direction in which the central axis ax of the internal space of the intermediate coil body 2 extends) are both scraped to the axial direction. It is processed into a shape along an orthogonal plane. That is, in the state shown in FIG. 2, there are lead wires and the like in the axial ends 21 and 22 of the intermediate coil body 2, and the intermediate coil body 2 has a step in the axial direction, but as shown in FIG. The lead wires and the like are removed, and the conducting wires forming the end portions 21 and 22 of the intermediate coil body 2 can be brought into contact with a plane perpendicular to the axial direction. At this time, the cross-sectional area of the conductors of the end portions 21 and 22 that have been machined is reduced from a predetermined value.

次に、プレス加工により中間コイル体２が加圧成形され異形断面コイルが形成される。すなわち、図４に示すように、中間コイル体２が型芯１とともに、台形形状を有する成形型３のキャビティ３ａ内に配置される。そして、図５に示すように、型芯１に嵌め込まれたプレス板４，５が型芯１に沿ってスライドされ、このプレス板４，５によって中間コイル体２が挟み込まれる。これにより、中間コイル体２の端部が軸方向に沿った上下方向から加圧され、中間コイル体２が成形型３のキャビティ３ａに沿った台形形状に変形される。その結果、部分によって導線の断面形状が異なり、かつ、全体として略台形形状の異形断面コイル８が生成される。   Next, the intermediate coil body 2 is pressure-formed by press working to form a modified cross-section coil. That is, as shown in FIG. 4, the intermediate coil body 2 is disposed together with the mold core 1 in the cavity 3 a of the mold 3 having a trapezoidal shape. As shown in FIG. 5, the press plates 4 and 5 fitted in the mold core 1 are slid along the mold core 1, and the intermediate coil body 2 is sandwiched between the press plates 4 and 5. As a result, the end of the intermediate coil body 2 is pressurized from the vertical direction along the axial direction, and the intermediate coil body 2 is deformed into a trapezoidal shape along the cavity 3 a of the mold 3. As a result, the cross-sectional shape of the conducting wire varies depending on the portion, and the modified cross-sectional coil 8 having a substantially trapezoidal shape as a whole is generated.

図６は、このプレス加工によって得られた異形断面コイル８の例を示す図である。図に示すように、異形断面コイル８は、断面が略台形形状となっており、図中の上部に向かうほど、導線の巻き幅（軸方向に直交する方向の幅）が大となる。また一方で、図中の上部に向かうほど、導線の断面の厚み（軸方向に沿った幅）が漸次に狭くなっている。すなわち導線は、その導線が延びる方向に沿って一定割合で漸次に変形している。   FIG. 6 is a diagram showing an example of the irregular cross-section coil 8 obtained by this press working. As shown in the figure, the deformed cross-section coil 8 has a substantially trapezoidal cross section, and the winding width of the conducting wire (the width in the direction orthogonal to the axial direction) increases toward the top in the figure. On the other hand, the thickness of the cross section of the conducting wire (width along the axial direction) gradually decreases toward the top in the figure. That is, the conducting wire is gradually deformed at a constant rate along the direction in which the conducting wire extends.

このような導線の漸次な変形は、図３に示すように中間コイル体２の端部２１，２２を平面加工した後に、加圧成形を行なうことにより実現される。例えば、平面加工を行なわずに図２に示す状態のまま中間コイル体２を上記と同様に加圧成形した場合を想定する。この場合は、プレス加工時において中間コイル体２の端部２１，２２はプレス板４，５に点で接触し、中間コイル体２の端部２１，２２の全体に均一な応力が与えられない。このことから、図７に示すように、この手法で得られる異形断面コイル８０は、一部の導線８１，８２が不規則かつ無秩序に変形することとなってしまう。   Such a gradual deformation of the conducting wire is realized by performing pressure forming after planarizing the end portions 21 and 22 of the intermediate coil body 2 as shown in FIG. For example, a case is assumed in which the intermediate coil body 2 is pressure-molded in the same manner as described above without performing the planar processing in the state shown in FIG. In this case, the end portions 21 and 22 of the intermediate coil body 2 are in contact with the press plates 4 and 5 at points during press working, and uniform stress is not applied to the entire end portions 21 and 22 of the intermediate coil body 2. . Therefore, as shown in FIG. 7, in the deformed cross-section coil 80 obtained by this method, some of the conducting wires 81 and 82 are irregularly and randomly deformed.

一方、本実施の形態のように中間コイル体２の端部２１，２２を平面加工した後に加圧成形すると、プレス加工時において中間コイル体２の端部２１，２２の全体がプレス板４，５に面で接触し、中間コイル体２の端部２１，２２の全体に均一な応力が与えられる。その結果、図６に示すように、導線が一定割合で漸次に変形された異形断面コイル８を得ることができる。   On the other hand, when the pressure forming is performed after the end portions 21 and 22 of the intermediate coil body 2 are planarized as in the present embodiment, the entire end portions 21 and 22 of the intermediate coil body 2 are pressed into the press plate 4 during the press working. 5 is in contact with the surface, and uniform stress is applied to the entire end portions 21 and 22 of the intermediate coil body 2. As a result, as shown in FIG. 6, it is possible to obtain a modified cross-sectional coil 8 in which the conducting wire is gradually deformed at a constant rate.

図６に示す異形断面コイル８が得られると、次に、図８に示すように、他の回路やコイルに接続するための引き出し線８ａ，８ｂとして、異形断面コイル８の端部の導線が一定長引き出される。そして、引き出し線８ａ，８ｂが所定の位置（例えば、図８の一点鎖線で示す位置９ａ，９ｂ）で切断され、図３に示す端部２１，２２の導線において平面加工により断面の一部が削られて断面積が減少した不完全な部分が排除される。   When the modified cross-section coil 8 shown in FIG. 6 is obtained, next, as shown in FIG. 8, as the lead wires 8a and 8b for connecting to other circuits and coils, the conductive wire at the end of the modified cross-section coil 8 is used. It is drawn for a certain length. Then, the lead wires 8a and 8b are cut at predetermined positions (for example, positions 9a and 9b shown by a one-dot chain line in FIG. 8), and a part of the cross section is formed by plane processing on the conductors of the end portions 21 and 22 shown in FIG. Incomplete parts with reduced cross-sectional area are removed.

続いて、異形断面コイル８の導線に絶縁材（例えばエナメル等）が塗布されて、絶縁被膜層が形成される。この絶縁材の塗布は、例えば、異形断面コイル８を軸方向に弾性変形の範囲内で引張り、螺旋状の導線の各巻き層間に隙間を形成した状態で、異形断面コイル８を溶融状態の絶縁材に浸漬することにより行なわれる。絶縁材の乾燥後、引張りを緩めれば、絶縁被膜層が形成された異形断面コイル８が生成される。なお、導線の各巻き層間の微少な隙間によって生じる毛細管現象を利用して絶縁被覆層を形成してもよい。   Subsequently, an insulating material (for example, enamel) is applied to the conducting wire of the modified cross-section coil 8 to form an insulating coating layer. The insulating material is applied, for example, by pulling the deformed cross-section coil 8 in the axial direction within the range of elastic deformation and forming a gap between the winding layers of the spiral conductive wire, This is done by dipping in the material. If the tension is loosened after the insulating material is dried, the modified cross-sectional coil 8 having the insulating coating layer formed thereon is generated. Note that the insulating coating layer may be formed by utilizing a capillary phenomenon generated by a minute gap between the winding layers of the conducting wire.

＜２．異形断面コイルの組込＞
次に、このようにして生成された異形断面コイル８を、モータのステータのコアに組み込む手法について説明する。まず、図９に示すように、モータの径方向に相当する方向に沿って放射状に等間隔で配置された複数のコア１２を有するコア構成体１３が準備される。複数のコア１２は、モータの軸中心側に相当する側が、仮接続部１１により互いに接続されている。異形断面コイル８は、このコア構成体１３の各コア１２に対して、モータの周縁側（軸中心側とは反対側）に相当する側からそれぞれ差し込み挿入される。この際、異形断面コイル８の台形形状において大となる側（導線の巻き幅が大で、導線の断面の厚みが小の側）が、モータの周縁側に相当する側となるように異形断面コイル８が挿入される。これにより、生成されるモータにおいてコイルの占積率を高めることができる。 <2. Incorporation of irregular cross-section coil>
Next, a method of incorporating the profile cross-sectional coil 8 generated in this way into the stator core of the motor will be described. First, as shown in FIG. 9, a core structure 13 having a plurality of cores 12 arranged radially at equal intervals along a direction corresponding to the radial direction of the motor is prepared. The plurality of cores 12 are connected to each other by temporary connection portions 11 on the side corresponding to the shaft center side of the motor. The odd-shaped cross-sectional coil 8 is inserted and inserted into each core 12 of the core structure 13 from the side corresponding to the peripheral side of the motor (the side opposite to the shaft center side). At this time, the irregular cross section is such that the side of the trapezoidal shape of the irregular cross section coil 8 (the side where the winding width of the conductive wire is large and the thickness of the cross section of the conductive wire is small) is the side corresponding to the peripheral side of the motor. The coil 8 is inserted. Thereby, the space factor of a coil can be raised in the generated motor.

その後、これら複数のコア１２の周縁側に相当する側を囲繞するリング状のリング部１４と、各コア１２の外端部とが溶接等により互いに固定される。   Thereafter, the ring-shaped ring portion 14 surrounding the side corresponding to the peripheral side of the plurality of cores 12 and the outer end portion of each core 12 are fixed to each other by welding or the like.

続いて、図１０に示すように、例えば３相モータの場合にあっては、異形断面コイル８の引き出し線に対してＵ相、Ｖ相、Ｗ相に応じた配線が行なわれる。そして、仮接続部１１がレーザ等により切断され、これにより異形断面コイル８が組み込まれたステータが完成する。この仮接続部１１の切断は必ずしも必要とされないが、モータの効率を確保するためには切断することが好ましい。   Subsequently, as shown in FIG. 10, for example, in the case of a three-phase motor, wiring corresponding to the U-phase, V-phase, and W-phase is performed on the lead wire of the deformed cross-sectional coil 8. And the temporary connection part 11 is cut | disconnected with a laser etc., and the stator in which the irregular cross-section coil 8 was integrated by this is completed. Although the temporary connection portion 11 is not necessarily cut, it is preferable to cut the temporary connection portion 11 in order to ensure the efficiency of the motor.

なお、コア構成体１３を準備することなく、互いに独立した複数のコアにそれぞれ異形断面コイル８を挿入し、この複数のコアをリング部１４に溶接等により取り付けてステータが製造されてもよい。   In addition, without preparing the core structure 13, the modified cross-section coil 8 may be inserted into each of a plurality of independent cores, and the plurality of cores may be attached to the ring portion 14 by welding or the like to manufacture the stator.

以上説明したように、本実施の形態の異形断面コイルの製造方法においては、中間コイル体２の端部が平面形状に加工された後、この中間コイル体２の端部が面接触により加圧されて、異形断面コイル８が生成される。したがって、製造されるコイルの端部付近における導線の無秩序な変形を効果的に防止できる。   As described above, in the method for manufacturing a modified cross-section coil according to the present embodiment, after the end portion of the intermediate coil body 2 is processed into a planar shape, the end portion of the intermediate coil body 2 is pressed by surface contact. As a result, the modified cross-section coil 8 is generated. Accordingly, it is possible to effectively prevent disordered deformation of the conducting wire in the vicinity of the end of the manufactured coil.

また、中間コイル体２を形成する際には、一定の断面形状を有する導線が型芯に単層にかつ均一に巻き付けられる。このことから、線材製造時における断面形状の制御が容易であり、また線材の巻き付け時においても均一に巻き付ければよく、巻き付け力の制御が容易である。このため、高効率なモータを実現するための異形断面コイル８を容易に製造できる。   Moreover, when forming the intermediate coil body 2, the conducting wire having a constant cross-sectional shape is uniformly wound around the mold core in a single layer. For this reason, it is easy to control the cross-sectional shape at the time of manufacturing the wire, and it is only necessary to uniformly wind the wire, so that the winding force can be easily controlled. For this reason, the odd-shaped cross-sectional coil 8 for implement | achieving a highly efficient motor can be manufactured easily.

＜３．変形例＞
以上、本発明の実施の形態について説明してきたが、この発明は上記実施の形態に限定されるものではなく様々な変形が可能である。 <3. Modification>
Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications are possible.

例えば、上記実施の形態では、削ることにより中間コイル体２の端部２１，２２を平面状に加工していたが、研磨や切断等の他の工法により加工してもよい。   For example, in the above embodiment, the end portions 21 and 22 of the intermediate coil body 2 are processed into a flat shape by cutting, but may be processed by other methods such as polishing and cutting.

また、上記実施の形態では、プレス加工における加圧方向として軸方向に沿った上下方向であると説明したが、軸方向に沿った水平方向であってもよい。   Moreover, although the said embodiment demonstrated that it was the up-down direction along an axial direction as a pressurization direction in press work, the horizontal direction along an axial direction may be sufficient.

また、上記実施形態においては、一度のプレス加工により異形断面のコイル８を製造すると説明したが、キャビティ３ａにおける台形形状の傾斜角が互いに異なる複数の成形型を準備しておき、これら複数の成形型を傾斜角の小さいものから順に用いた複数回のプレス加工により中間コイル体２を段階的に変形させて、最終的に目的とする形状の異形断面コイル８を製造してもよい。これによれば、安定した断面形状の異形断面コイル８を製造できる。   Further, in the above embodiment, it has been described that the coil 8 having an irregular cross-section is manufactured by a single press working. However, a plurality of molding dies having different trapezoidal inclination angles in the cavity 3a are prepared, and the plurality of moldings are prepared. The intermediate coil body 2 may be deformed stepwise by a plurality of press processes using the molds in ascending order of inclination angle, and finally the modified cross-section coil 8 having a desired shape may be manufactured. According to this, the irregular cross-sectional coil 8 having a stable cross-sectional shape can be manufactured.

また、中間コイル体２がキャビティ３ａの台形形状に接触する位置、あるいは、角度を変更しながら中間コイル体２を段階的に変形させ、導線の各層の変形や導線の巻きくずれを防止するようにしてもよい。   Further, the intermediate coil body 2 is deformed step by step while changing the position or angle at which the intermediate coil body 2 contacts the trapezoidal shape of the cavity 3a to prevent deformation of each layer of the conductive wire or winding of the conductive wire. May be.

また、上記実施形態においては、モータのステータのコアに配置される異形断面コイル８の製造方法について示しているが、モータのロータのコアに配置される異形断面コイルであってもよい。   Moreover, in the said embodiment, although the manufacturing method of the irregular cross-section coil 8 arrange | positioned at the core of the stator of a motor is shown, the irregular cross-section coil arrange | positioned at the core of the rotor of a motor may be sufficient.

導線を螺旋状に巻き付けた状態を示す斜視図である。It is a perspective view which shows the state which wound the conducting wire helically. 巻き付けによって形成された中間コイル体を示す図である。It is a figure which shows the intermediate coil body formed by winding. 軸方向の端部が平面に削られた中間コイル体を示す図である。It is a figure which shows the intermediate coil body by which the edge part of the axial direction was shaved on the plane. 中間コイル体が成形型のキャビティ内にセットされた様子を示す図である。It is a figure which shows a mode that the intermediate coil body was set in the cavity of a shaping | molding die. 中間コイル体がプレス板によって加圧された様子を示す図である。It is a figure which shows a mode that the intermediate coil body was pressurized with the press board. プレス加工によって得られた異形断面コイルの一例を示す図である。It is a figure which shows an example of the irregular cross-section coil obtained by press work. 導線が無秩序に変形した異形断面コイルの一例を示す図である。It is a figure which shows an example of the irregular cross-section coil which the conducting wire deform | transformed disorderly. 異形断面コイルの端部の導線が引き出された様子を示す図である。It is a figure which shows a mode that the conducting wire of the edge part of the irregular cross-section coil was pulled out. コアに対する異形断面コイルの組込方法説明図である。It is explanatory drawing of the incorporating method of the irregular cross-section coil with respect to a core. コアに対する異形断面コイルの組込方法説明図である。It is explanatory drawing of the incorporating method of the irregular cross-section coil with respect to a core.

符号の説明Explanation of symbols

１ 型芯
２ 中間コイル体
３ 成形型
４，５ プレス板
８ 異形断面コイル
１２ コア
２９ 導線 DESCRIPTION OF SYMBOLS 1 Type | mold core 2 Intermediate | middle coil body 3 Forming die 4,5 Press board 8 Profile cross-section coil 12 Core 29 Conductor

Claims (4)

異形断面コイルの製造方法であって、
（ａ）線材を型芯に螺旋状に巻いて中間コイル体を形成する工程と、
（ｂ）前記中間コイル体の軸方向の端部を、前記軸方向に直交する平面に沿った形状に加工する工程と、
（ｃ）加工された前記中間コイル体の端部を前記軸方向に沿って加圧することにより、前記中間コイル体を成形型のキャビティに応じた形状に変形させて異形断面のコイルを製造する工程と、
を備えることを特徴とする異形断面コイルの製造方法。 A method of manufacturing a modified cross-section coil,
(A) a step of spirally winding a wire around a mold core to form an intermediate coil body;
(B) processing the axial end of the intermediate coil body into a shape along a plane perpendicular to the axial direction;
(C) A step of producing a coil with a deformed cross section by deforming the intermediate coil body into a shape corresponding to the cavity of the mold by pressurizing the processed end portion of the intermediate coil body along the axial direction. When,
The manufacturing method of the irregular cross-section coil characterized by the above-mentioned. 請求項１に記載の異形断面コイルの製造方法において、
（ｄ）前記工程（ｃ）の後、前記異形断面コイルの端部の前記線材において前記工程（ｂ）の加工により断面積が減少した部分を切断する工程、
をさらに備えることを特徴とする異形断面コイルの製造方法。 In the manufacturing method of the irregular cross-section coil according to claim 1,
(D) After the step (c), cutting the portion of the wire rod at the end of the irregular cross-section coil whose cross-sectional area has decreased due to the processing of the step (b);
The manufacturing method of the irregular cross-section coil characterized by the above-mentioned. 請求項１または２に記載の異形断面コイルの製造方法において、
前記線材は一定断面形状とされ、前記型芯に均一に巻き付けられることを特徴とする異形断面コイルの製造方法。 In the manufacturing method of the irregular cross-section coil according to claim 1 or 2,
The method of manufacturing a modified cross-section coil, wherein the wire has a constant cross-sectional shape and is uniformly wound around the mold core. 請求項１ないし３のいずれかに記載の異形断面コイルの製造方法において、
前記成形型は段階的なキャビティを有する複数の成形型からなり、各成形型による複数回の加圧成形によって段階的な変形により所定形状の異形断面のコイルを製造することを特徴とする異形断面コイルの製造方法。
In the manufacturing method of the irregular cross-section coil according to any one of claims 1 to 3,
The mold includes a plurality of molds having stepped cavities, and a deformed cross section having a predetermined shape is manufactured by stepwise deformation by multiple times of pressure molding with each mold. Coil manufacturing method.
JP2004340283A 2004-11-25 2004-11-25 Method for manufacturing irregular cross-section coil Expired - Fee Related JP4500654B2 (en)

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JP4613918B2 (en) * 2007-03-12 2011-01-19 トヨタ自動車株式会社 Coil manufacturing method
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DE102019202049A1 (en) * 2019-02-15 2020-08-20 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. METHOD OF MANUFACTURING A HELICAL BODY WITH COMPRESSION OF THE HELICAL
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JPS6015438U (en) * 1983-07-09 1985-02-01 打本　友二 spring roller
JPH088136A (en) * 1994-06-15 1996-01-12 Murata Mfg Co Ltd Manufacture of air-core coil
JPH11252842A (en) * 1998-02-27 1999-09-17 Hitachi Ltd Molded coil element, its manufacture, core, its manufacture and dynamoelectric machine
JP2004080861A (en) * 2002-08-12 2004-03-11 Sumitomo Electric Ind Ltd Motor component and motor

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Publication number Priority date Publication date Assignee Title
JPS6015438U (en) * 1983-07-09 1985-02-01 打本　友二 spring roller
JPH088136A (en) * 1994-06-15 1996-01-12 Murata Mfg Co Ltd Manufacture of air-core coil
JPH11252842A (en) * 1998-02-27 1999-09-17 Hitachi Ltd Molded coil element, its manufacture, core, its manufacture and dynamoelectric machine
JP2004080861A (en) * 2002-08-12 2004-03-11 Sumitomo Electric Ind Ltd Motor component and motor

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