JP2898451B2 - Coil winding device for slotless motor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coilless winding device for a slotless motor for manufacturing a coil mounted on an annular stator core having no slot.

[0002]

2. Description of the Related Art Slotless motors have the advantage of suppressing the generation of electromagnetic noise and torque ripple due to harmonic magnetic flux due to the presence of a stator slot, and are therefore required to have low noise and low torque ripple. It is expected to expand to.

[0003] The stator of this type of slotless motor is
In the case of a general adduction motor, a plurality of coils for forming a rotating magnetic field are assembled into a cylindrical shape that matches the inner peripheral shape of a simple annular stator core without slots, and integrated by resin molding, etc. Then, such a cylindrical coil is inserted into the stator core and fixed.

[0004] In this case, conventionally, the cylindrical coil usually has a two-layer structure (eg, Japanese Patent Publication No. 57-2).
Such a coil for a two-layer structure can be wound using a simple concentric winding form.

[0005]

In the case of a slotless motor, the gap between the stator and the rotor has a large effect on its characteristics. Generally, as the gap increases, the gap becomes larger. As a result, the leakage magnetic flux increases, so that the output torque decreases and the power factor deteriorates. Therefore, it is desirable to set the gap between the stator and the rotor as small as possible.

In order to reduce the gap between the stator and the rotor, it is considered that the cylindrical coil has a single-layer structure and its radial thickness is reduced as the most effective and reliable means. However, when such a single-layer cylindrical coil is formed by a plurality of coils, the coils are wound by using a conventional simple concentric winding form. The coil side cross-sectional shape of the coil is in a dumpling state, making it difficult to form a cylindrical coil with good characteristics and inevitably increasing the radial thickness of the cylindrical coil. There was a problem that it was difficult to achieve the intended purpose.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to provide a coil capable of forming a single-layer cylindrical coil for a slotless motor without increasing its radial thickness. It is an object of the present invention to provide a coilless winding device for a slotless motor suitable for manufacturing a coilless motor.

[0008]

According to the present invention, in order to attain the above object, the number of turns distribution on the coil side decreases in the direction toward the inner periphery, and a plurality of turns are distributed in the radial direction at the turn number decreasing portion. In a winding apparatus for manufacturing a coil for a slotless motor which is assembled into a cylindrical coil by being sequentially arranged in a circumferential direction in an overlapped state, a space for winding a coil conductor in a state where the coil conductors are aligned with each other. Providing a first mold and a second mold in which a portion is formed, and matching the inner peripheral shape of the cylindrical coil to a position corresponding to one coil side among positions facing the space in the first mold. A first shaping surface that determines the shape of the turn-number-reduced portion is formed at a position corresponding to the other coil side and faces the space in the second mold. Location A second arc surface having a shape conforming to the outer peripheral shape of the cylindrical coil is formed at a position facing the first shaping surface, and the number of turns is formed at a position facing the first arc surface. It is configured to form a second shaping surface that determines the shape of the reduced portion.

In this case, each of the first mold and the second mold may be divided into two in the coil length direction, and the divided parts may be connected in such a manner that the dimensions between them can be adjusted. .

[0010]

In the state where the first mold and the second mold are matched,
A coil is formed by winding a coil conductor a predetermined number of times around a space formed between the dies. In the coil formed in this manner, one of the coil sides has a shape corresponding to the space defined by the first arc surface and the second shaping surface, and the other coil side has the second arc surface. A shape corresponding to the space defined by the surface and the first shaping surface,
The number-of-turns distribution on the coil sides is reduced toward the inner circumference.

When a plurality of coils are used to form a cylindrical coil, the coils are sequentially arranged in the circumferential direction while being superposed in the radial direction at the reduced number of turns. In the formed cylindrical coil, the adjacent coil sides overlap in the radial direction at the reduced portion of the turn number distribution, so that only a single-layer structure is required. In this case, one coil side of each coil is formed by a first arc surface having a shape matching the inner peripheral shape of the cylindrical coil, and the other coil side has a shape matching the outer peripheral shape of the cylindrical coil. Since the cylindrical coil is formed by the second arc surface, the cylindrical coil formed by the combination of these coils has a state in which the inner peripheral shape and the outer peripheral shape have less irregularities.

In the case where the first mold and the second mold are each divided into two in the coil length direction, the coil length of the wound coil is changed by adjusting the dimension between the divided portions. Therefore, versatility as a winding device can be enhanced.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to FIGS.

FIG. 6 shows a schematic cross-sectional structure of an adduction type slotless motor. In this FIG.
The rotor 2 supported in the frame 1 via a bearing (not shown) has a configuration including a permanent magnet 3 for forming four magnetic poles. A three-phase four-pole stator 4 provided in the frame 1 so as to surround the rotor 2 includes a stator core 5 fixed to the inner periphery of the frame 1 and an inner periphery of the stator core 5. And a cylindrical coil 6 composed of a plurality of coils 6a for forming a rotating magnetic field, which is mounted on the motor.

The stator core 5 is formed in a simple cylindrical shape without slots by laminating a plurality of annularly formed electromagnetic steel plates. In this embodiment, the stator 4 has three phases and four poles, and accordingly, twelve coils 6a are provided.

FIG. 7 shows the cross-sectional shape of the coil 6a together with an example of its arrangement. However, four coils 6a of the first phase (U phase) are U1 to U4, respectively, four coils 6a of the second phase (V phase) are V1 to V4, respectively, and four coils 6a of the third phase (W phase). Are represented by W1 to W4, respectively.

In FIG. 7, coils U1-U4, V1-
V4, W1 to W4 are configured as cylindrical coils 6 along the inner circumference of the stator core 5 by sequentially arranging in a circumferential direction such that each pair of coil sides occupies 90 degrees in mechanical angle. And the following conditions are satisfied.

... Each coil 6a has such a shape that the turn number distribution in the radial direction of the stator core 5 on the coil side decreases toward the inner circumference.

... In the state of being formed as the cylindrical coil 6, adjacent coil sides are radially overlapped with each other at the above-mentioned turn number reduced portion (in this example, the entire coil side).

The turn number distribution of each coil side like... Continuously changes within a range of 60 electrical degrees, and in this example, it changes sinusoidally.

FIGS. 1 to 4 show the coil 6 described above.
a configuration of a winding device 7 for producing a
This will be described below.

Referring to FIGS. 1 and 2, a winding device 7 comprises a lower die 8 as a first die and an upper die 9 as a second die. In the matched state, a space 10 (see FIG. 1) for winding a coil conductor is formed between the two. The lower die 8 and the upper die 9
Is held by screwing a bolt 11 and a nut 12 that pass therethrough.

As shown in FIG. 3, the lower mold 8 is formed in a rectangular shape as a whole, and is configured as follows (a) to (c).

(A) At the center, an abutting surface portion 13 having a shape (an oval shape) corresponding to the innermost peripheral shape of the coil 6a is formed so as to bulge. Further, a through hole 1 through which the bolt 11 penetrates is provided at the center of the abutting surface portion 13.
3a, and positioning projections 13b and 13c are formed on both sides of the through-hole 13a.

(B) A position corresponding to one coil side of the coil 6a (a position corresponding to the lamination length L of the stator core 5 shown in FIG. 3) matches the inner peripheral shape of the cylindrical coil 6. A first arc surface 14 (shown by a grid-like oblique line in FIG. 3) having a defined shape is formed. In other words, the curvature of the first arc surface 14 is the curvature R of the inner peripheral surface of the cylindrical coil 6 shown in FIG.
It is set equal to i.

(C) The position corresponding to the other coil side of the coil 6a (the stack length L of the stator core 5 also shown in FIG. 3)
The first shaping surface 15 that determines the shape of the turn-reduced portion of the coil 6a, that is, the sine wave shape,
(Shown by a grid-like hatched band in FIG. 3).

As shown in FIG. 4, the upper mold 9 is formed in a rectangular shape as a whole, and is configured as shown in (d) to (f) below.

(D) At the center portion, a butting surface portion 16 which abuts against the butting surface portion 13 of the lower die 8 is formed so as to bulge into a shape (an oval shape) corresponding to the innermost peripheral shape of the coil 6a. I have. In addition, the butted surface portion 16 includes
A through hole 16a through which the bolt 11 penetrates is formed at the center thereof, and engagement holes 16 into which the projections 13b and 13c of the lower die 8 are fitted on both sides of the through hole 16a.
b, 16c are formed.

(E) A position corresponding to one coil side of the coil 6a (a position corresponding to the lamination length L of the stator core 5 shown in FIG. 4) coincides with the outer peripheral shape of the cylindrical coil 6. A second arc surface 17 having a shape (indicated by a grid-like hatched band in FIG. 4) is formed. That is, the curvature of the second arc surface 17 is the curvature R of the outer peripheral surface of the cylindrical coil 6 shown in FIG.
It is set equal to o.

(F) Position corresponding to the other coil side of the coil 6a (the stack length L of the stator core 5 also shown in FIG. 4)
The second shaping surface 18 for determining the shape of the turn-reduced portion of the coil 6a, that is, the sine wave shape,
(Indicated by a grid-like hatched band in FIG. 4).

In a state where the lower die 8 and the upper die 9 are matched with each other, a coil conductor is wound around the space 10 formed between the respective dies 8 and 9 a predetermined number of times, as shown in FIG. Such a coil 6a can be formed,
The coil 6a has one coil side defined by the first arc surface 14 and the second shaping surface 18, and the other coil side defined by the second arc surface 17 and the first shaping surface 15. Will be defined. As a result, in the coil 6a, the turn number distribution of each coil side decreases toward the inner circumference, and the change state of the turn number distribution corresponds to the shapes of the first shaping surface 15 and the second shaping surface 18. It becomes sinusoidal.

As shown in FIG. 7, in the cylindrical coil 6 formed by using the twelve coils 6a as described above, the adjacent coil sides are formed in the radial direction at the reduced portion of the turn number distribution as described above. Therefore, a single-layer structure is sufficient, and the distribution of the total number of turns in the overlapping portion of the coil side as described above is made uniform in the circumferential direction. Therefore, there is no possibility that the radial thickness of each part of the entire cylindrical coil 6 becomes large, and the gap between the rotor 2 and the stator 4 can be reduced.

One of the coil sides of each coil 6a has a first shape which matches the inner peripheral shape of the cylindrical coil 6.
And the other coil side is formed by the second arc surface 17 having a shape conforming to the outer peripheral shape of the cylindrical coil 6. The coil 6 has a state in which the inner peripheral shape and the outer peripheral shape have few irregularities, and the gap between the rotor 2 and the stator 4 can be reduced from this surface as well.

In the above embodiment, each coil 6a (U1
ＵU4, V1ＶV4, W1ＷW4), the turn number distribution of the coil side decreases toward the inner circumference of the coil, and the decreasing state is continuous in a sinusoidal approximation in the range of 60 electrical degrees. Although it is configured to change, the change state of the turn number distribution on the coil side does not necessarily need to be the sine wave approximation shape as described above, and may be each configuration as described below. .

FIGS. 8 and 9 show a second embodiment of the present invention. In the second embodiment, as shown in FIG.
Each coil 6b (U1 to U4,
V1 to V4, W1 to W4) are in a state where the distribution of the number of turns on the coil side continuously changes linearly within a range of 60 degrees in electrical angle.

As shown in FIG. 9, the winding device 7A for manufacturing the coil 6b includes a first shaping surface 1 on the lower die 8 side.
5A is formed in a linear shape corresponding to the shape of the turn-reduced portion of the coil 6b, and the second shaping surface 18A on the upper mold 9 side.
Is formed in a linear shape corresponding to the shape of the turn-reduced portion of the coil 6b.

FIGS. 10 and 11 show a third embodiment of the present invention. In the third embodiment, as shown in FIG. 10, each coil 6c (U1
U4, V1 to V4, and W1 to W4) are in a state in which the turn number distribution of the coil side sequentially changes in three steps within a range of 60 electrical degrees.

As shown in FIG. 11, the winding device 7B for manufacturing the coil 6c is such that the first shaping surface 15B on the lower die 8 side has a stepped shape corresponding to the shape of the turn-reduced portion of the coil 6c. The second shaping surface 18B on the upper mold 9 side is formed in a shape.
Are formed in a stepped shape corresponding to the shape of the turn-reduced portion of the coil 6c.

FIGS. 12 and 13 show a fourth embodiment of the present invention. In the fourth embodiment, as shown in FIG. 12, each coil 6d (U1
U4, V1 to V4, and W1 to W4) change the turn number distribution of the coil side continuously in a linear shape up to a substantially intermediate portion in an electrical angle range of 60 degrees, and change stepwise at the intermediate portion. In addition, the remaining portion continuously changes in a linear shape.

As shown in FIG. 13, the winding device 7C for manufacturing the coil 6d has a state in which the first shaping surface 15C on the lower die 8 side corresponds to the shape of the turn-reduced portion of the coil 6d. And the second shaping surface 18C on the upper mold 9 side is
Similarly, the coil 6d is formed in a state corresponding to the shape of the portion where the number of turns is reduced.

FIGS. 14 and 15 show a fifth embodiment of the present invention. In the fifth embodiment, as shown in FIG. 14, each coil 6e (U1
U4, V1 to V4, W1 to W4), the distribution of the number of turns on the coil side was calculated by dividing each 1 /
It is in a state of continuously changing in a linear shape only at three positions.

As shown in FIG. 15, the winding device 7D for manufacturing the coil 6e has a state in which the first shaping surface 15D on the lower die 8 side corresponds to the shape of the turn-reduced portion of the coil 6e. And the second shaping surface 18D on the upper mold 9 side is
Similarly, the coil 6e is formed in a state corresponding to the shape of the portion where the number of turns is reduced.

FIGS. 16 and 17 show a sixth embodiment of the present invention. In the sixth embodiment, as shown in FIG. 16, each coil 6f (U1
The turn number distribution of the coil sides U4, V1 to V4, and W1 to W4) is set such that only a part near the inner periphery thereof changes linearly.

As shown in FIG. 17, the winding device 7E for manufacturing the coil 6f has a state in which the first shaping surface 15E on the lower die 8 side corresponds to the shape of the turn-reduced portion of the coil 6f. And the second shaping surface 18E on the upper mold 9 side is
Similarly, the coil 6f is formed in a state corresponding to the shape of the portion where the number of turns is reduced.

FIGS. 18 and 19 show a seventh embodiment of the present invention. In the seventh embodiment, as shown in FIG. 18, each coil 6g (U1
The turn number distribution of the coil sides U4, V1 to V4, and W1 to W4) is such that only approximately one half of the coil side near the inner circumference is reduced.

As shown in FIG. 19, the winding device 7F for manufacturing the coil 6g has a state in which the first shaping surface 15F on the lower die 8 side conforms to the shape of the turn-reduced portion of the coil 6g. And the second shaping surface 18F on the upper mold 9 side is
Similarly, it is formed in a state corresponding to the shape of the portion where the number of turns of the coil 6g is reduced.

FIGS. 20 and 21 show an eighth embodiment of the present invention. In the eighth embodiment, as shown in FIG. 20, each coil 6h (U1
The turn number distribution of the coil sides U4, V1 to V4, and W1 to W4) is linearly changed only at both sides of a part near the inner periphery.

As shown in FIG. 21, the winding device 7G for manufacturing the coil 6g has a state in which the first shaping surface 15G on the lower die 8 side conforms to the shape of the turn-reduced portion of the coil 6h. And the second shaping surface 18G on the upper mold 9 side is
Similarly, the coil 6h is formed in a state corresponding to the shape of the portion where the number of turns is reduced.

Even in the case of the second to eighth embodiments as described above, the cylindrical coil 6 having a single-layer structure can be formed. In each of such embodiments, the cylindrical coil 6 can be formed. This eliminates the possibility that the radial thickness of each part of the whole becomes large.

When skew is applied to the cylindrical coil 6, FIGS. 22 and 23 show a ninth embodiment of the present invention.
As described above, the butt surface 13 of the lower die 8 may be inclined by an angle corresponding to the skew angle, and the butt surface 16 of the upper die 9 may be inclined by an angle corresponding to the skew angle.

FIGS. 24 to 27 show a tenth embodiment of the present invention, which will be described below.

That is, in FIG. 24, the lower die 19 as the first die is a split die 20 in which the lower die 8 of the first embodiment is divided into two in the coil length direction by removing the center portion thereof.
21 are provided, and these are connected by a connection plate 22. In this case, the connecting plate 22 includes
A plurality of bolt holes 22a are formed in a line for fixing to the 0 and 21. By selecting the bolt holes 22a, the dimension between the split dies 20 and 21 can be adjusted. The split dies 20 and 21 are formed with projections 20a and 21a for alignment, respectively.

Referring to FIG. 25, the second upper mold 23
Are divided dies 24 and 25 in which the upper die 9 in the first embodiment is divided into two in the coil length direction by removing a central portion thereof.
And these are connected by a connection plate 26. In this case, the connecting plate 26 includes the split dies 24, 2
A plurality of bolt holes 27a are formed in a row for fixing to the die 5, and the dimensions between the split dies 24 and 25 can be adjusted by selecting the bolt holes 27a. The split dies 24 and 25 have engagement holes 24a and 2a into which the projections 20a and 21a on the lower die 19 are respectively fitted.
5a are formed.

According to the present embodiment configured as described above, the coil length of the wound coil can be changed by adjusting the dimensions between the split dies 20 and 21 and between the split dies 24 and 25. Therefore, versatility can be improved.
Moreover, between the split molds 20 and 21 and between the split molds 24 and 25,
26 and 27, the wound coil can be easily skewed, and the versatility can be improved from this aspect as well.

[0055]

As is apparent from the above description, according to the first aspect of the present invention, the turn number distribution on the coil side is formed in a shape that decreases toward the inner circumference, and a plurality of the turn number reduction portions are formed. In a winding apparatus for manufacturing a coil for a slotless motor assembled into a cylindrical coil by being sequentially arranged in a circumferential direction while being superposed in a radial direction, a coil conductor is wound in a state where the coil conductors are aligned with each other. A first mold and a second mold in which a space portion is formed, and the inner periphery of the cylindrical coil is located at a position corresponding to one coil side among positions facing the space portion in the first mold. Forming a first arc surface having a shape conforming to the shape, forming a first shaping surface at a position corresponding to the other coil side to determine a shape of the turn-reduced portion, and forming the space in a second mold; Coming to the department Among the positions, a second arc surface having a shape matching the outer peripheral shape of the cylindrical coil is formed at a position facing the first shaping surface, and the second arc surface is formed at a position facing the first arc surface. Since the second shaping surface for determining the shape of the turn-reduced portion is formed, a single-layer cylindrical coil for a slotless motor can be formed without increasing its radial thickness. Can be manufactured, and the characteristics of a slotless motor using the cylindrical coil can be improved.

According to the second aspect of the present invention, since the first mold and the second mold are each divided into two in the coil length direction and the dimension between the divided portions is adjustable, the coil to be wound is formed. Can be easily changed, and the versatility can be improved.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a first embodiment of the present invention.

FIG. 2 is a side view showing the disassembled state.

FIG. 3 is a view for explaining the shape of a first mold.

FIG. 4 is a view for explaining the shape of a second mold.

FIG. 5 is a perspective view of a coil.

FIG. 6 is a cross-sectional view of a slotless motor.

FIG. 7 is a plan view showing the shape and arrangement of coils.

FIG. 8 is a view corresponding to FIG. 7, showing a second embodiment of the present invention.

FIG. 9 is a diagram corresponding to FIG. 1;

FIG. 10 is a view corresponding to FIG. 7, showing a third embodiment of the present invention.

FIG. 11 is a diagram corresponding to FIG. 1;

FIG. 12 is a view corresponding to FIG. 7, showing a fourth embodiment of the present invention;

FIG. 13 is a diagram corresponding to FIG. 1;

FIG. 14 is a view corresponding to FIG. 7, showing a fifth embodiment of the present invention.

FIG. 15 is a diagram corresponding to FIG. 1;

FIG. 16 is a view corresponding to FIG. 7, showing a sixth embodiment of the present invention.

FIG. 17 is a diagram corresponding to FIG. 1;

FIG. 18 is a view corresponding to FIG. 7, showing a seventh embodiment of the present invention.

FIG. 19 is a diagram corresponding to FIG. 1;

FIG. 20 is a view corresponding to FIG. 7, showing an eighth embodiment of the present invention;

FIG. 21 is a diagram corresponding to FIG. 1;

FIG. 22 is a plan view of a first mold showing a ninth embodiment of the present invention.

FIG. 23 is a plan view of a second mold.

FIG. 24 is a plan view of a first mold showing a tenth embodiment of the present invention.

FIG. 25 is a plan view of a second mold.

FIG. 26 is a plan view of the first mold in different use states;

FIG. 27 is a plan view of the second mold in different use states;

[Explanation of symbols]

In the figure, 1 is a frame, 2 is a rotor, 3 is a permanent magnet, 4 is a stator, 5 is a stator core, 6 is a cylindrical coil, 6a to 6a.
h, U1 to U4, V1 to V4, W1 to W4 are coils,
7, 7A to 7G are winding devices, 8, 19 are lower dies (first die), 9, 23 are upper dies (second die), 10 is a space part,
4 denotes a first arc surface, 15, 15A to 15G denote a first shaping surface, 17 denotes a second arc surface, and 18, 18A to 18G denote second shaping surfaces.

Continuation of the front page (72) Inventor Sadami Yano 2121 Nagoya, Asahi-cho, Mie-gun, Mie Prefecture Inside Mie Plant, Toshiba Corporation (56) References JP-A-58-212348 (JP, A) JP-A-56-115149 (JP, A) (58) Field surveyed (Int. Cl. ⁶ , DB name) H02K 15/04-15/095

Claims (2)

(57) [Claims] 1. A cylinder having a shape in which the number-of-turns distribution on the coil side decreases in the direction toward the inner circumference, and a plurality of turns are sequentially arranged in the circumferential direction in a state of being overlapped in the radial direction at the turn-number-reduced portion. A winding apparatus for manufacturing a coil for a slotless motor assembled into a spiral coil, comprising: a first die and a second die in which a space for winding a coil conductor is formed in a state where they are matched with each other. A first arc surface having a shape matching the inner peripheral shape of the cylindrical coil is formed at a position corresponding to one coil side among positions facing the space in the first mold. In addition, a first shaping surface that determines the shape of the turn-number-reduced portion is formed at a position corresponding to the other coil side, and among the positions facing the space in the second mold, the first shaping is performed. Face to face A second arc surface having a shape coinciding with the outer peripheral shape of the cylindrical coil at a position to be formed, and a shape of the turn-reduced portion determined at a position facing the first arc surface. A coil winding device for a slotless motor coil, wherein a shaping surface is formed. 2. The first mold and the second mold are each divided into two parts in the coil length direction, and each divided part is connected so that the dimension between them can be adjusted. A coil winding device for a coil for a slotless motor according to claim 1.