JPS6135780B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a coreless armature used in a so-called coreless motor.

Conventionally, as shown in FIG. 1a, a square covered conductor 1 is used.
A cylindrical core body 3 is a sheet-like conducting wire bundle 2 which is made by bundling wires parallel to each other at equal pitches so as not to overlap each other.
is wound in a spiral shape to form an inner layer coil, and the sheet-shaped conducting wire bundle 2 is wrapped from above the inner layer coil.
is spirally wound in the opposite direction to form an outer layer coil 5 as shown in FIG.
is cut at regular intervals L to form a cylindrical armature coil 6 as shown in FIG. A method for manufacturing a coreless armature has been developed in which the armature coils 6 are connected to each other as shown in FIG. 2b to form a closed loop as the entire armature coil 6. By the way, in the manufacturing method of such a coreless armature, in order to connect the coil wires 8 and 9, the arrow P in FIG.
A method of irradiating a laser beam in the direction shown in is used, but since there is an insulating coating 30 between the core wires of the coil wires 8 and 9, the adjacent portions of the coil wires 8 and 9 are Even if the coil wires 13 were irradiated with a laser beam, a nugget 15 was formed on each of the coil wires 8 and 9 separately, as shown in FIG. 3, and a good electrical connection could not be achieved. Therefore, the present inventors formed a protrusion 12 for welding on the coil wire 8 on the inner layer side as shown in FIGS. 4a and 4b, and bent the protrusion 12 as shown by the dotted line in FIG. After that, we tried a method of irradiating a welding laser beam from the direction of arrow P as shown in Figure b, but the wire shapes of the coil wire 8 on the inner layer side and the coil wire 9 on the outer layer side were different. Therefore, the heat capacity is different, and welding with a laser beam is unstable. In addition, in this method, the laser beam irradiation needs to be performed perpendicularly to the cut end 7, so if welding is to be carried out deeply, the molten part will overlap the adjacent coil as shown in Figure 4c. There was a drawback that there was a risk that the wires would reach the wires 8 and 9 and cause shoots.

The present invention has been made to eliminate these drawbacks of the conventional example, and by aligning the wire shapes of the coil wires of the inner layer and outer layer to be welded together, the heat capacity is equalized and welding stability is improved. Manufacture of a coreless armature in which the welding laser beam can be irradiated from the side of the cut end, thereby eliminating the risk of the molten part reaching the adjacent coil wire and causing shortening. The purpose is to provide a method.

The structure of the present invention will be described below with reference to the illustrated embodiments. As shown in FIGS. 5 to 7, a sheet-shaped conductive bundle 2 is formed by bundling rectangular covered conductor wires 1 in parallel at equal pitches so as not to overlap each other. is spirally wound around a cylindrical core 3 to form an inner layer coil 4, and the sheet-shaped conducting wire bundle 2 is spirally wound in the opposite direction from above the inner layer coil 4 to form an outer layer coil 5. , both the coils 4 and 5 are cut at regular intervals L to form a cylindrical armature coil 6, and the coil wires 8 and 9 adjacent to each other in the radial direction are cut at the cut end 7 of the armature coil 6. In a method for manufacturing a coreless armature in which the entire armature coil 6 is connected to form a closed loop, the cut ends 7 of both the inner and outer coil wires 8 and 9 are connected.
The radial center portion 10 of each coil wire 8, 9,
By cutting only one side of each of the coil wires 8 and 9 as a boundary, welding protrusions 12 are formed on the cut ends 7 of each of the coil wires 8 and 9. The length of the protruding piece 12 on the side closer to the adjacent portion 13 of 9 is shortened, and the shortened protruding piece 12b is
After bending the long protruding piece 12a to the side of the other long protruding piece 12a, the long protruding piece 12a is bent so as to overlap the short protruding piece 12b, and the contact portion 14 of both protruding pieces 12a and 12b is laser welded from the radial direction. It was designed to perform the following. In the embodiment shown in FIG. 5, the protrusion 12 formed on the coil wire 9 on the outer layer side is shorter, but this relationship may be reversed, and the coil wire 8 on the inner layer side is shorter. The protruding piece 12 formed in the above may be made shorter. However, when irradiating the laser beam for welding, it is more convenient to irradiate the beam from the side of the armature coil 6, so the protrusion 12 on the outer layer side can be shortened as shown in FIG. It is more desirable. Difference h ₁ in height between short protruding piece 12b and long protruding piece 12a and length of short protruding piece 12b
_h2 is determined so that both protruding pieces 12a and _12b can be overlapped as shown in FIG. It is almost equal to the length ₂ of the part, and the difference h ₁ in height between both protrusions 12a and 12b is equal to the length 2 of both protrusions 12a and 12b.
The length of the vertically overlapping portion of 12b is approximately equal to ₁ . However, the laser beam
As shown in FIG. b, when the contact portion 14 of both protruding pieces 12a, 12b is irradiated from the side of armature coil 6 as shown by arrow Q, both protruding pieces 12a, 1 for welding
2b melts and forms nugget 1 as shown in Figure 6c.
5 is formed.

Next, FIG. 7 shows a process for forming both protrusions 12a and 12b for welding on the coil wires 8 and 9. First, in FIG. 7a, 3a is a cylindrical core body, in which ring-shaped grooves 16 are bored at equal intervals L. Sheet-shaped conducting wire bundle 2 is attached to the cylindrical core body 3a.
After spirally winding to form the inner layer coil 4, a cutter 17 is used to form a stepped portion 18 corresponding to the elongated protrusion 12a. Next, after winding the outer layer coil 5 in a reverse spiral direction from above the inner layer coil 4, a step portion 20 corresponding to the short protrusion 12b is formed using a cutter 19, as shown in FIG. 7b. Finally, if the inner layer coil 4 is cut with the cutter 21, the fifth
It is possible to obtain short protruding pieces 12b and long protruding pieces 12a as shown in the figure.

The present invention is constructed as described above, and by cutting only one side of the cut ends of both the inner and outer layer coil wires with the radial center of each coil wire as a border, the cut ends of each coil wire are cut. A protruding piece for welding is formed on the part, and a short protruding piece, which is the protruding piece on the side closer to the adjacent parts of both the inner and outer layer coil wires, is shortened to the other long protruding piece. After bending, the long protrusion is bent so that it overlaps the short protrusion, and laser welding is applied from the radial direction to the contact area of both protrusions, so the inner and outer layers are welded together. By aligning the wire shapes of the coil wires, the heat capacity of both coil wires can be made almost equal, and the degree of melting of both coil wires can be made almost equal, which has the advantage of improving welding stability. be. Furthermore, in the present invention, the short protrusion is bent toward the long protrusion, and then the long protrusion is bent so as to overlap the short protrusion, so the laser beam is irradiated on the side of the armature coil. This method has the advantage that even if the welding time is increased, there is no risk of the molten portion reaching the adjacent coil strands and causing shoots, unlike in the conventional method.

As mentioned in the description of the embodiments of the present invention, if the short protrusions are arranged on the outer layer side and the long protrusions are arranged on the inner layer side, the part to be welded will be on the outside of the armature coil. Since it is exposed on both sides, it becomes easier to perform laser welding.

[Brief explanation of the drawing]

Figures 1a and b are perspective views of a conventional example, Figure 2a is a perspective view of a coreless armature, Figure b is a perspective view of the same essential parts as above, and Figure 3 is a side sectional view of a coil wire. , Figure 4a,
b is a side sectional view showing an example of a conventional welded part, c is a partially see-through front view of the same as above, FIG. 5 is a perspective view of a main part of an embodiment of the present invention, and FIGS. 6 a, b, c
FIG. 7 is a side sectional view of the main part of the same as above, and FIGS. 7a, b, and c are side sectional views of both the inner and outer layer coil wires showing the manufacturing process of the welding protrusion shown in the above. 1 is a coated conducting wire, 2 is a sheet-like conducting wire bundle, 3 is a cylindrical core, 4 is an inner layer coil, 5 is an outer layer coil, 6 is an armature coil, 7 is a cut end, 8 and 9 are coil wires, 10 , 11 is a central part, 12 is a protruding piece, 12a is a long protruding piece, 12b is a short protruding piece, 13 is an adjacent part, 14
is the contact part.

Claims (1)

[Claims] 1. An inner layer coil is formed by winding a sheet-shaped conductor wire bundle made of rectangular covered conductor wires bundled parallel to each other at equal pitches so as not to overlap each other, around a cylindrical core body, and from above the inner layer coil. The above-mentioned sheet-shaped conducting wire bundle is spirally wound in opposite directions to form an outer layer coil, both coils are cut at regular intervals to form a cylindrical armature coil, and at the cut end of the armature coil, In a method for manufacturing a coreless armature in which coil wires adjacent to each other in the radial direction are connected to form a closed loop as a whole armature coil, the cut ends of both the inner and outer coil wires are connected to each other to form a closed loop as a whole armature coil. By cutting off only one side of the strand at the radial center of the wire,
A protrusion for welding is formed on the cut end of each coil wire, and the length of the protrusion on the side closer to the adjacent portion of both the inner and outer coil wires is shortened, and the short protrusion is shortened. The method is characterized by bending one piece to the side of the other long protrusion, then bending the long protrusion so that it overlaps the short protrusion, and laser welding the contact portion of both protrusions from the radial direction. A method for manufacturing a iron-free core armature.