U.S. patent application number 09/776638 was filed with the patent office on 2001-09-06 for coil assembly of rotating electrical machinery and method for producing the same, and stator of rotating electric machinery using the same coil assembly.
Invention is credited to Adachi, Katsumi, Asao, Yoshihito, Matsui, Hiroshi, Morishita, Akira, Murakami, Tsutomu, Oketani, Naohiro, Oohashi, Atsushi, Ozaki, Hironori, Takahashi, Tsuyoshi, Takizawa, Takushi.
Application Number | 20010019234 09/776638 |
Document ID | / |
Family ID | 27342266 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010019234 |
Kind Code |
A1 |
Murakami, Tsutomu ; et
al. |
September 6, 2001 |
Coil assembly of rotating electrical machinery and method for
producing the same, and stator of rotating electric machinery using
the same coil assembly
Abstract
The invention provides a coil member of rotating electrical
machinery, by which improvements in the mass production and
downsizing thereof are enabled, which is a coil assembly for
rotating electrical machinery, consisting of a plurality of coil
combinations mounted at iron core slots, wherein the respective
coil combinations 14 are inserted into slots at pitches equivalent
to an appointed number of slots, and are formed of an integral coil
member 21 in which the first and the second linear portions 21A and
21B alternately disposed at the inner layer side and the outer
layer side in the slots, and the first and the second turning
portions 21C and 21D for connecting the first and second linear
portions 21A and 21B adjacent to each other outward of one end side
and outward of the other end side in the lengthwise direction of
the slots are integrated together. And, the first linear portion
21A of the appointed coil member 211 thereof, and the second linear
portion 21B of another coil member 211 are laminated and disposed
in the same slots.
Inventors: |
Murakami, Tsutomu; (Tokyo,
JP) ; Ozaki, Hironori; (Tokyo, JP) ; Oketani,
Naohiro; (Tokyo, JP) ; Morishita, Akira;
(Tokyo, JP) ; Matsui, Hiroshi; (Tokyo, JP)
; Takahashi, Tsuyoshi; (Tokyo, JP) ; Adachi,
Katsumi; (Tokyo, JP) ; Takizawa, Takushi;
(Tokyo, JP) ; Asao, Yoshihito; (Tokyo, JP)
; Oohashi, Atsushi; (Tokyo, JP) |
Correspondence
Address: |
SUGHRUE, MION, ZINN, MACPEAK & SEAS, PLLC
Suite 800
2100 Pennsylvania Avenue, N.W.
Washington
DC
20037-3213
US
|
Family ID: |
27342266 |
Appl. No.: |
09/776638 |
Filed: |
February 6, 2001 |
Current U.S.
Class: |
310/180 ;
310/184; 310/201 |
Current CPC
Class: |
H02K 15/0478 20130101;
H02K 3/14 20130101 |
Class at
Publication: |
310/180 ;
310/184; 310/201 |
International
Class: |
H02K 003/12; H02K
003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 7, 2000 |
JP |
2000-028644 |
Sep 27, 2000 |
JP |
2000-293217 |
Dec 28, 2000 |
JP |
2000-399698 |
Claims
What is claimed is:
1. A coil assembly of rotating electrical machinery, which is
mounted in a plurality of slots formed on the circumferential
surface of an iron core at appointed pitches P, having a plurality
of coil combinations, in which the respective coil combinations
comprises a combination of a first coil member and a second coil
member; wherein each of said first coil member and second coil
member includes: a plurality of first linear portions disposed at
pitches equal to "N" times ("N" is any natural number) said pitches
P and respectively inserted in one of said plurality of slots; a
plurality of second linear portions disposed at pitches equal to
"N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots; a plurality of first turning portions for
coupling said respective first linear portions with said respective
second linear portions adjacent to one side of said respective
first liner portions at one end side of said slots; and a plurality
of second turning portions for coupling said respective first
linear portions with said respective second linear portions
adjacent to other side of said respective first liner portions at
the other end side of said slots; wherein said respective first
linear portions, first turning portions, second linear portions and
second turning portions are formed so as to be continued to each
other by one strip member; and said first coil member and second
coil member are combined so that in an appointed slot of said
plurality of slots, the first linear portion of said first coil
members is located at the inner layer side and the second linear
portion of said second coil members is located at the outer layer
side, and, in a slot separated by "N" slots from said appointed
slot, the first linear portion of said second coil member is
located at the inner layer side and the second linear portion of
said first coil member is located at the outer layer side.
2. A coil assembly of rotating electrical machinery as set forth in
claim 1, wherein said first turning portions and said second
turning portions, respectively, have an inclined portion extending
said respective appointed slot to a turning point, and an inclined
portion extending from said slot separated by "N" slots from said
appointed slot to said turning point; and said turning point is
displaced so as to be positioned nearer said slot separated by "N"
slots from said appointed slot than said appointed slot.
3. A coil assembly of rotating electrical machinery as set forth in
claim 1, wherein said first and second coil members are formed so
that said respective first linear portions, first turning portions,
second linear portions and second turning portions are continued by
one strip member having an almost rectangular section.
4. A coil assembly of rotating electrical machinery as set forth in
claim 1, wherein said first and second coil members are formed so
that said respective first linear portions, first turning portions,
second linear portions and second turning portions are continued by
one strip member having almost a circular section.
5. A coil assembly of rotating electrical machinery, which is
mounted in a plurality of slots formed on the circumferential
surface of an iron core at appointed pitches P, having a plurality
of coil combinations, in which the respective coil combinations
comprises a combination of a first coil member to a fourth coil
member; wherein each of said first coil member to said fourth coil
member includes: a plurality of first linear portions disposed at
pitches equal to "N" times ("N" is any natural number) said pitches
P and respectively inserted in one of said plurality of slots; a
plurality of second linear portions disposed at pitches equal to
"N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots; a plurality of first turning portions for
coupling said respective first linear portions with said respective
second linear portions adjacent to one side of said respective
first liner portions at one end side of said slots; and a plurality
of second turning portions for coupling said respective first
linear portions with said respective second linear portions
adjacent to other side of said respective first liner portions at
the other end side of said slots; wherein said respective first
portions, first turning portions, second linear portions and second
turning portions are formed so as to be continued to each other by
one strip member; said first coil member and second coil member are
combined so that in an appointed slot of said plurality of slots,
the first linear portion of said first coil members is located in
the first layer and the second linear portion of said second coil
members is located in the fourth layer, and, in a slot separated by
"N" slots from said appointed slot, the first linear portion of
said second coil member is located in the first layer and the
second linear portion of said first coil member is located in the
fourth layer; and said third coil member and fourth coil member are
combined so that in the appointed slot of said plurality of slots,
the first linear portion of said third coil members is located in
the second layer and the second linear portion of said fourth coil
members is located in the third layer, and, in the slot separated
by "N" slots from said appointed slot, the first linear portion of
said fourth coil member is located in the second layer and the
second linear portion of said third coil member is located in the
third layer.
6. A method for producing a coil assembly of rotating electrical
machinery, comprising the steps of: winding step for winding a
plurality of strip members coaxial with each other so that said
plurality of strip coil members, respectively, are provided with: a
plurality of the first linear portions located on the first plane;
a plurality of the second linear portions located at the second
plane parallel to said first plane; a plurality of the first
turning portions for coupling said respective first linear portions
with said respective second linear portions adjacent to one side of
said respective first liner portions; and a plurality of the second
turning portions for coupling said respective first linear portions
with said second linear portions adjacent to the other side of said
respective first liner portions and displacing step for displacing
said respective first linear portions on said first plane and said
second linear portions on the second plane so that these linear
portions move in parallel to each other, by displacing the first
end portions of said respective first linear portions of said
plurality of coil members on said first plane, and the first end
portions of said respective second linear portions thereof on said
second plane in the direction opposed to each other, and
concurrently displacing the second end portions of said respective
linear portions of said respective coil members on said second
plane and the second end portions of said respective first linear
portions thereof on said first plane in the direction opposed to
each other; wherein in said displacing step, a plurality of coil
assemblies in which two coil members of said plurality of coil
members are combined are formed, said respective coil assemblies
have said respective second linear portions of the second coil
members positioned on said respective first linear portions of the
first coil members, and have said respective first linear portions
of said second coil members positioned below said respective second
linear portions of said first coil members.
7. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 6, wherein said plurality of coil
assemblies are, respectively, combined and inserted so that, in an
appointed slot of a plurality of slots formed on an iron core at
appointed pitches P, the first linear portions of said first coil
members are located on the first layer, and the second linear
portions of said second coil members are located on the second
layer, and in slots separated by "N" slots from the appointed slot,
the first linear portions of said second coil members are located
on the first layer and the second linear portions of said first
coil members are located on the second layer.
8. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, further comprising the step of
pressing the respective coil members so that the respective first
linear portions on said first plane are caused to approach the
respective second linear portions on said second plane.
9. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 8, wherein said pressing step is
carried out before said displacing step.
10. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 8, wherein said pressing step is
carried out after said displacing step.
11. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, wherein, before inserting said
respective coil combinations into the slots after said displacing
step, lead-out conductors are formed at necessary coil members and
necessary connections are carried out.
12. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, in which said respective first
turning portions and said respective second turning portions have
an inclined portion extending from said respective appointed slots
to a turning point, and an inclined portion extending from a slot
separated by "N" slots from said appointed slots to said turning
point, further comprising the step of displacing said turning point
so that said turning point is located nearer the slot separated by
"N" slots from said appointed slots than said appointed slots.
13. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, wherein, when said displacing
step is terminated, both-end portions of said plurality of coil
members are collected and disposed at the same side as that of any
one of said plurality of the first turning portions and said
plurality of the second turning portions.
14. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, wherein, when said displacing
step is terminated, both-end portions of said plurality of coil
members are distributed to the same side as that of said plurality
of the first turning portions and the same side as that of said
plurality of the second turning portions and disposed thereat.
15. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 7, wherein in said displacing
step, the first end portions of the respective first linear
portions of said plurality of coil members, the first end portions
of said respective second linear portions thereof, the second end
portions of the respective second linear portions of the respective
coil members, and the second end portions of the respective first
linear portions thereof are, respectively, displaced by separate
movable members.
16. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 15, wherein said movable member
having a plurality of pins are used as said respective movable
members.
17. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 15, wherein said movable member
having a plurality of blades is used as said respective movable
members, and the respective blades are brought into facial contact
with the linear portions of the respective coil members.
18. A method for producing a coil assembly of rotating electrical
machinery, comprising the steps of: bending step for forming a
plurality of linear portions and a plurality of inclined portions
in the form such that they are inclined at an appointed angle with
respect to respective adjacent linear portions between said
adjacent linear portions and said inclined portion is placed
therebetween, by bending a plurality of strip coil members almost
parallel to each other on a certain plane a plurality of times; and
folding and overlapping step for folding and overlapping the
respective coil members of said respective inclined portions one
after another at the position where said coil members are equally
divided into one half section and the other half section in its
lengthwise direction so that said other half section crosses and
overlaps said one half section at said appointed angle; wherein, in
said folding and overlapping step, a plurality of coil combinations
in which two coil members of said plurality of coil members are
combined are formed, said respective coil combinations have said
respective second linear portions of said second coil members
positioned on respective first linear portions of said first coil
members, and have respective first linear portions of said second
coil members positioned below respective second linear portions of
said first coil members.
19. A method for producing a coil assembly of rotating electrical
machinery, as set forth in claim 18, wherein said plurality of coil
combinations are, respectively, combined and inserted so that, in
an appointed slot of a plurality of slots formed on an iron core at
appointed pitches P, the first linear portions of said first coil
members are located on the first layer, and the second linear
portions of said second coil members are located on the second
layer, and in slots separated by "N" slots from the appointed slot,
the first linear portions of said second coil members are located
on the first layer and the second linear portions of said first
coil members are located on the second layer.
20. A stator of rotating electric machinery comprising a stator
iron core having a plurality of slots formed along the
circumferential surface at appointed pitches P and a coil assembly
mounted the slots of said stator iron core, and having a plurality
of coil combinations, in which the respective coil combinations
comprises a coil combinations of a first coil members and a second
coil members, wherein each of said first coil members and said
second coil members including: a plurality of first linear portions
disposed at pitches equal to "N" times ("N" is any natural number)
said pitches P and respectively inserted in one of said plurality
of slots; a plurality of second linear portions disposed at pitches
equal to "N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots; a plurality of first turning portions for
coupling said respective first linear portions with said respective
second linear portions adjacent to one side of said respective
first liner portions thereto at one end side of said slots; and a
plurality of second turning portions for coupling said respective
first linear portions with said respective second linear portions
adjacent to the other side of said respective first liner portions
at the other end side of said slots; wherein said respective first
linear portions, first turning portions, second linear portions and
second turning portions are formed so as to be continued to each
other by one strip member; and said first coil member and second
coil member are combined so that in an appointed slot of said
plurality of slots, the first linear portion of said first coil
members is located at the inner layer side and the second linear
portion of said second coil members is located at the outer layer
side, and, in a slot separated by "N" slots from said appointed
slot, the first linear portion of said second coil member is
located at the inner layer side and the second linear portion of
said first coil member is located at the outer layer side.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a coil assembly of rotating
electrical machinery such as a vehicle alternate current generator,
etc., that is incorporated in a truck, etc., and a method for
producing the same coil assembly, and a stator of rotating electric
machinery using the same coil assembly,
[0003] 2. Description of the Prior Art
[0004] In order to make the vehicle alternate current generator
more compact and more powerful for its size, it is mandatory to
improve the space factor inside each slot of the core of the stator
winding, and to arrange more neatly and increase the density of the
cross-over parts on the outside of the slots of the stator winding,
i.e., the coil end parts. Numerous improvements have been proposed
as exemplified by Japanese Patent No. 2927288 concerning this
point.
[0005] FIGS. 27 (A) and (B) are perspective views of the essential
parts of the stator winding of an automobile alternator of the
prior art viewed from the front and rear sides respectively, and
FIG. 28 is a perspective view of the conductor segment used on the
stator winding of the vehicle alternate current generator shown in
FIG. 27.
[0006] These drawings show a conductor segment 1 comprising an
inner layer conductor part 1a, an outer layer conductor part 1b and
a turning portion 1c, which is formed into a U-shape by bending a
copper band-like member. Multiple conductor segments 1 formed as
such are arranged on the rear side of a stator iron core 2 neatly
aligning the turning portions 1c. Next, the turning portion 1c is
bent in such a way that the inner layer conductor part 1a and the
outer layer conductor part 1b will be separated circumferentially
by a specified number of slots as shown in FIG. 27 (B). Next,
insert the outer layer conductor part 1b on the deeper side in the
slot depth direction, and the inner layer conductor part 1a on the
shallower side in the slot depth direction (not shown in the
drawing), and join the end parts of the specified conductor segment
1 that are protruding on the front side by means of welding,
brazing, and other similar methods as shown in FIG. 27 (A), thereby
forming a conjunction part 3a to constitute a coil member 3.
[0007] The stator winding of the vehicle alternate current
generator of the prior art were constituted by inserting a short
U-shaped conductor segment 1 into the slots of the stator iron core
2 from the rear side and then joining the ends together that are
protruding on the front side. Therefore, the work was inefficient
and the productivity was low because it was necessary to insert
numerous short conductor segments 1 into the slots of the stator
iron core 2 and then join the ends one by one. Moreover, since the
end portions have to be protruded further to allow the ends to be
clamped by a fixture for the joining process, it was difficult to
produce a smaller alternator.
SUMMARY OF THE INVENTION
[0008] The invention was developed to solve such problems and
shortcomings as described above. It is therefore an object of the
invention to provide a coil assembly for a rotating electrical
machinery, for which mass production can be improved, and whose
downsizing is enabled.
[0009] Also, it is another object of the invention to provide a
method for producing a coil assembly for a rotating electrical
machinery, by which improvements in the mass production and
downsizing thereof are enabled.
[0010] In addition, it is yet another object of the invention to
provide a stator for rotating electrical machinery, by which
improvements in the mass production and downsizing thereof are
enabled.
[0011] According to this invention, a coil assembly of rotating
electrical machinery, which is mounted in a plurality of slots
formed on the circumferential surface of an iron core at appointed
pitches P, having a plurality of coil combinations, in which the
respective coil combinations comprises a combination of a first
coil member and a second coil member;
[0012] wherein each of said first coil member and second coil
member includes:
[0013] a plurality of first linear portions disposed at pitches
equal to "N" times ("N" is any natural number) said pitches P and
respectively inserted in one of said plurality of slots;
[0014] a plurality of second linear portions disposed at pitches
equal to "N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots;
[0015] a plurality of first turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to one side of said respective first liner
portions at one end side of said slots; and
[0016] a plurality of second turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to other side of said respective first liner
portions at the other end side of said slots;
[0017] wherein said respective first linear portions, first turning
portions, second linear portions and second turning portions are
formed so as to be continued to each other by one strip member;
and
[0018] said first coil member and second coil member are combined
so that in an appointed slot of said plurality of slots, the first
linear portion of said first coil members is located at the inner
layer side and the second linear portion of said second coil
members is located at the outer layer side, and, in a slot
separated by "N" slots from said appointed slot, the first linear
portion of said second coil member is located at the inner layer
side and the second linear portion of said first coil member is
located at the outer layer side.
[0019] Therefore, the coil assembly of rotating electrical
machinery, by which improvements in the mass production and
downsizing thereof are enabled, can be provided.
[0020] Also, according to this invention, the coil assembly of
rotating electrical machinery, wherein said first turning portions
and said second turning portions, respectively, have an inclined
portion extending said respective appointed slot to a turning
point, and an inclined portion extending from said slot separated
by "N" slots from said appointed slot to said turning point; and
said turning point is displaced so as to be positioned nearer said
slot separated by "N" slots from said appointed slot than said
appointed slot.
[0021] Further, according to this invention, the coil assembly of
rotating electrical machinery, wherein said first and second coil
members are formed so that said respective first linear portions,
first turning portions, second linear portions and second turning
portions are continued by one strip member having an almost
rectangular section.
[0022] Furthermore, according to this invention, the coil assembly
of rotating electrical machinery, wherein said first and second
coil members are formed so that said respective first linear
portions, first turning portions, second linear portions and second
turning portions are continued by one strip member having almost a
circular section.
[0023] In addition, a coil assembly of rotating electrical
machinery, according to this invention, which is mounted in a
plurality of slots formed on the circumferential surface of an iron
core at appointed pitches P, having a plurality of coil
combinations, in which the respective coil combinations comprises a
combination of a first coil member to a fourth coil member;
[0024] wherein each of said first coil member to said fourth coil
member includes:
[0025] a plurality of first linear portions disposed at pitches
equal to "N" times ("N" is any natural number) said pitches P and
respectively inserted in one of said plurality of slots;
[0026] a plurality of second linear portions disposed at pitches
equal to "N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots;
[0027] a plurality of first turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to one side of said respective first liner
portions at one end side of said slots; and
[0028] a plurality of second turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to other side of said respective first liner
portions at the other end side of said slots;
[0029] wherein said respective first portions, first turning
portions, second linear portions and second turning portions are
formed so as to be continued to each other by one strip member;
[0030] said first coil member and second coil member are combined
so that in an appointed slot of said plurality of slots, the first
linear portion of said first coil members is located in the first
layer and the second linear portion of said second coil members is
located in the fourth layer, and, in a slot separated by "N" slots
from said appointed slot, the first linear portion of said second
coil member is located in the first layer and the second linear
portion of said first coil member is located in the fourth layer;
and
[0031] said third coil member and fourth coil member are combined
so that in the appointed slot of said plurality of slots, the first
linear portion of said third coil members is located in the second
layer and the second linear portion of said fourth coil members is
located in the third layer, and, in the slot separated by "N" slots
from said appointed slot, the first linear portion of said fourth
coil member is located in the second layer and the second linear
portion of said third coil member is located in the third
layer.
[0032] Therefore, the coil assembly of rotating electrical
machinery, by which improvements in the mass production and
downsizing thereof are enabled, can be provided.
[0033] Also, a method for producing a coil assembly of rotating
electrical machinery, according to this invention, comprising the
steps of:
[0034] winding step for winding a plurality of strip members
coaxial with each other so that said plurality of strip coil
members, respectively, are provided with: a plurality of the first
linear portions located on the first plane; a plurality of the
second linear portions located at the second plane parallel to said
first plane; a plurality of the first turning portions for coupling
said respective first linear portions with said respective second
linear portions adjacent to one side of said respective first liner
portions; and a plurality of the second turning portions for
coupling said respective first linear portions with said second
linear portions adjacent to the other side of said respective first
liner portions and
[0035] displacing step for displacing said respective first linear
portions on said first plane and said second linear portions on the
second plane so that these linear portions move in parallel to each
other, by displacing the first end portions of said respective
first linear portions of said plurality of coil members on said
first plane, and the first end portions of said respective second
linear portions thereof on said second plane in the direction
opposed to each other, and concurrently displacing the second end
portions of said respective linear portions of said respective coil
members on said second plane and the second end portions of said
respective first linear portions thereof on said first plane in the
direction opposed to each other;
[0036] wherein in said displacing step, a plurality of coil
combinations in which two coil members of said plurality of coil
members are combined are formed, said respective coil combinations
have said respective second linear portions of the second coil
members positioned on said respective first linear portions of the
first coil members, and have said respective first linear portions
of said second coil members positioned below said respective second
linear portions of said first coil members.
[0037] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
improvements in the mass production and downsizing thereof are
enabled.
[0038] Further, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said plurality of coil combinations are, respectively, combined and
inserted so that, in an appointed slot of a plurality of slots
formed on an iron core at appointed pitches P, the first linear
portions of said first coil members are located on the first layer,
and the second linear portions of said second coil members are
located on the second layer, and in slots separated by "N" slots
from the appointed slot, the first linear portions of said second
coil members are located on the first layer and the second linear
portions of said first coil members are located on the second
layer.
[0039] Further, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, further
comprising the step of pressing the respective coil members so that
the respective first linear portions on said first plane are caused
to approach the respective second linear portions on said second
plane.
[0040] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which further
downsizing thereof are enabled.
[0041] Further, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said pressing step is carried out before said displacing step.
[0042] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said pressing step is carried out after said displacing step.
[0043] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which the
insulation thereof can be improved.
[0044] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery,
wherein, before inserting said respective coil combinations into
the slots after said displacing step, lead-out conductors are
formed at necessary coil members and necessary connections are
carried out.
[0045] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
efficiency in the wiring work can be improved.
[0046] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, in
which said respective first turning portions and said respective
second turning portions have an inclined portion extending from
said respective appointed slots to a turning point, and an inclined
portion extending from a slot separated by "N" slots from said
appointed slots to said turning point, further comprising the step
of displacing said turning point so that said turning point is
located nearer the slot separated by "N" slots from said appointed
slots than said appointed slots.
[0047] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which further
downsizing thereof are enabled.
[0048] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery,
wherein, when said displacing step is terminated, both-end portions
of said plurality of coil members are collected and disposed at the
same side as that of any one of said plurality of the first turning
portions and said plurality of the second turning portions.
[0049] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
efficiency in connection work can be improved.
[0050] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery,
wherein, when said displacing step is terminated, both-end portions
of said plurality of coil members are distributed to the same side
as that of said plurality of the first turning portions and the
same side as that of said plurality of the second turning portions
and disposed thereat.
[0051] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
efficiency in the connection work can be further improved.
[0052] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
in said displacing step, the first end portions of the respective
first linear portions of said plurality of coil members, the first
end portions of said respective second linear portions thereof, the
second end portions of the respective second linear portions of the
respective coil members, and the second end portions of the
respective first linear portions thereof are, respectively,
displaced by separate movable members.
[0053] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
improvements in the mass production and downsizing thereof are
enabled.
[0054] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said movable member having a plurality of pins are used as said
respective movable members.
[0055] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said movable member having a plurality of blades is used as said
respective movable members, and the respective blades are brought
into facial contact with the linear portions of the respective coil
members.
[0056] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
improvements in the mass production and downsizing thereof are
enabled as a matter of course, and insulation property can be
further improvement.
[0057] In addition, according to this invention, a method for
producing a coil assembly of rotating electrical machinery,
comprising the steps of:
[0058] bending step for forming a plurality of linear portions and
a plurality of inclined portions in the form such that they are
inclined at an appointed angle with respect to respective adjacent
linear portions between said adjacent linear portions and said
inclined portion is placed therebetween, by bending a plurality of
strip coil members almost parallel to each other on a certain plane
a plurality of times; and
[0059] folding and overlapping step for folding and overlapping the
respective coil members of said respective inclined portions one
after another at the position where said coil members are equally
divided into one half section and the other half section in its
lengthwise direction so that said other half section crosses and
overlaps said one half section at said appointed angle;
[0060] wherein, in said folding and overlapping step, a plurality
of coil combinations in which two coil members of said plurality of
coil members are combined are formed, said respective coil
combinations have said respective second linear portions of said
second coil members positioned on respective first linear portions
of said first coil members, and have respective first linear
portions of said second coil members positioned below respective
second linear portions of said first coil members.
[0061] Therefore, it is possible to provide a method for producing
a coil assembly for rotating electrical machinery, by which
improvements in the mass production and downsizing thereof are
enabled.
[0062] Furthermore, according to this invention, the method for
producing a coil assembly of rotating electrical machinery, wherein
said plurality of coil combinations are, respectively, combined and
inserted so that, in an appointed slot of a plurality of slots
formed on an iron core at appointed pitches P, the first linear
portions of said first coil members are located on the first layer,
and the second linear portions of said second coil members are
located on the second layer, and in slots separated by "N" slots
from the appointed slot, the first linear portions of said second
coil members are located on the first layer and the second linear
portions of said first coil members are located on the second
layer.
[0063] In addition, according to this invention, a stator of
rotating electric machinery, comprising:
[0064] a stator iron core having a plurality of slots formed along
the circumferential surface at appointed pitches P and a coil
assembly mounted the slots of said stator iron core, and having a
plurality of coil combinations, in which the respective coil
combinations comprises a coil combinations of a first coil members
and a second coil members,
[0065] wherein each of said first coil members and said second coil
members including:
[0066] a plurality of first linear portions disposed at pitches
equal to "N" times ("N" is any natural number) said pitches P and
respectively inserted in one of said plurality of slots;
[0067] a plurality of second linear portions disposed at pitches
equal to "N" times said pitches P, positioned at the middle of said
respective first linear portions and inserted into one of said
plurality of slots;
[0068] a plurality of first turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to one side of said respective first liner
portions thereto at one end side of said slots; and
[0069] a plurality of second turning portions for coupling said
respective first linear portions with said respective second linear
portions adjacent to the other side of said respective first liner
portions at the other end side of said slots;
[0070] wherein said respective first linear portions, first turning
portions, second linear portions and second turning portions are
formed so as to be continued to each other by one strip member;
and
[0071] said first coil member and second coil member are combined
so that in an appointed slot of said plurality of slots, the first
linear portion of said first coil members is located at the inner
layer side and the second linear portion of said second coil
members is located at the outer layer side, and, in a slot
separated by "N" slots from said appointed slot, the first linear
portion of said second coil member is located at the inner layer
side and the second linear portion of said first coil member is
located at the outer layer side.
[0072] Therefore, it is possible to provide a stator of rotating
electrical machinery, by which improvements in the mass production
and downsizing thereof are enabled.
[0073] In according to this invention, a coil assembly of rotating
electrical machinery and a method for producing the same, and a
stator of rotating electric machinery using the same coil assembly,
respectively, can bring about the following features, advantages
and effects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1 is a perspective view showing the appearance of a
stator of an alternate current generator for vehicles, to which a
coil assembly according to the first embodiment of the invention is
applied;
[0075] FIG. 2 develops the construction of the coil assembly in
FIG. 1 together with a stator, wherein (A) is a developed front
elevational view, and (B) is a side elevational view taken along
the line B-B in (A);
[0076] FIG. 3 is a developed front elevational view showing a part
of the construction of the coil assembly in FIG. 1;
[0077] FIG. 4 is a perspective view showing a part of the
construction of one coil member in FIG. 3;
[0078] FIG. 5 is a perspective view showing a part of the
construction of one coil combination in FIG. 3;
[0079] FIG. 6 shows a production process of a coil assembly in FIG.
3, wherein (A) is a view showing a winding step, and (B) is a view
showing a displacing step;
[0080] FIG. 7 shows the construction of plate-like stator iron
core, wherein (A) is a plan view, and (B) is a side elevational
view;
[0081] FIG. 8 is a plan view showing the construction of a
plate-like winding core on which a coil is wound;
[0082] FIGS. 9(A)(B)(C)(D) is a side elevational view showing a
pressing step and a displacing step after a coil member is spirally
wound;
[0083] FIG. 10 is an exemplary view explaining the displacing step
in FIG. 6 in detail;
[0084] FIGS. 11(A)(B) is a block diagram showing two different
types of a coil assemblies by comparison;
[0085] FIG. 12 is a view showing a winding step which differs from
the coil in FIG. 6;
[0086] FIG. 13 is a view showing a displacing step which differs
from the coil in FIG. 6;
[0087] FIG. 14 is a developed view showing the construction of a
coil assembly differing from that in FIG. 3;
[0088] FIG. 15 is a developed view showing the construction of a
coil assembly further differing from that in FIG. 3;
[0089] FIG. 16 is a view showing one process in a method for
producing a coil assembly of rotating electric machinery according
to the second embodiment of the invention;
[0090] FIG. 17 is a view showing one process differing from the
process in FIG. 6 in a method for producing a coil assembly of
rotating electric machinery according to the second embodiment of
the invention;
[0091] FIG. 18 is a block diagram showing the steps of a method for
producing a coil assembly of rotating electric machinery according
to the second embodiment of the invention;
[0092] FIG. 19 is a perspective view showing the appearance of a
stator of an alternate current generator for vehicles, which is
different from that to which a coil according to the first or the
second embodiments is applied;
[0093] FIG. 20 is a view showing a method differing from that in
FIG. 16 showing the process for producing a coil assembly according
to the second embodiment of the invention;
[0094] FIG. 21 is a perspective view showing the appearance of a
stator of an alternate current for vehicles to which a coil
according to the third embodiment of the invention is applied;
[0095] FIG. 22 is a perspective view explaining the profile of the
first coil member in FIG. 21;
[0096] FIG. 23 is a perspective view explaining the array of the
first coil member in FIG. 21;
[0097] FIG. 24 is a perspective view explaining the profile of the
second coil member in FIG. 21;
[0098] FIG. 25 is a perspective view explaining the array of the
second coil member in FIG. 21;
[0099] FIG. 26 is a perspective view explaining the array of
combinations of a coil combination in FIG. 21;
[0100] FIG. 27(A) is a perspective view showing the major parts of
a prior art stator coil for an alternate current generator for
vehicles, which is observed from its front side, and (B) is a
perspective view thereof when being observed from its rear side;
and
[0101] FIG. 28 is a perspective view showing the construction of a
conductor segment that is applied to the stator coil for an
alternate current generator for vehicles in FIG. 27.
EMBODIMENTS OF THE INVENTION
[0102] Hereinafter, a description is given of embodiments of the
invention on the basis of the accompanying drawings:
[0103] Embodiment 1
[0104] FIG. 1 is a perspective view showing the appearance of a
stator of an alternate current generator for a vehicle, to which a
coil assembly according to a first embodiment of the invention is
applied. FIG. 2 shows the construction of the coil assembly in FIG.
1, which is developed together with the stator, wherein (A) is a
developed front elevational view, and (B) is a side elevational
view observed along the line B-B in (A). FIG. 3 is a developed
front elevational view showing the developed construction of the
coil assembly in FIG. 1. FIG. 4 is a perspective view showing a
part of the construction of one coil assembly in FIG. 3. FIG. 5 is
a perspective view showing a part of the construction of one coil
combination in FIG. 3.
[0105] FIG. 6 shows the production process of the coil member in
FIG. 3, wherein (A) shows a winding step, and (B) shows a
displacing step. FIG. 7 shows the construction of a flat-type
stator iron core, wherein (A) is a plan view, and (B) is a side
elevational view. FIG. 8 is a plan view showing the construction of
a plate-shaped winding core for winding a coil. FIG. 9 is a side
elevational view showing a pressing step and a displacing step
after a coil member is spirally wound. FIG. 10 is an exemplary view
explaining the detail of the displacing step in FIG. 6. FIG. 11 is
a block diagram showing two types of different steps of a coil
assembly by comparison. FIG. 12 is a view showing a winding step
differing from FIG. 6 that shows a coil member. FIG. 13 is a view
showing a displacing step differing from FIG. 6 that shows a coil
member. FIG. 14 is a developed view showing the construction of a
coil assembly differing that in FIG. 3. FIG. 15 is a developed view
showing the construction of a coil assembly further differing from
that in FIG. 3.
[0106] In the drawings, a flat type stator iron core 11A has a
plurality of slots 13 formed on one side thereof. A coil member 21
is provided with an insulation film and, as shown in FIG. 4, is
formed of an integral strip or band-shaped member having a
rectangular section, which has a width W and a thickness T. And,
the coil member 21 is formed of the first linear portion 21A and
the second linear portion 21B alternately disposed at the inner
layer side (the inner circumferential side of the stator iron core
11) and the outer layer side (the outer circumferential side of the
stator iron core 11) in slots 13 while shifting them by the width W
in the lamination direction at pitches P equivalent to appointed
slots, and the first turning portion 21C and the second turning
portion 21D that connect these linear portions 21A and 21B outward
of one end side and outward of the other end side of the slots 13
in the lengthwise direction. As shown in FIG. 5, a coil combination
14 is constructed by laminating and disposing the first linear
portion 21A of one coil member 22 formed as described above and the
second linear portion 21B of the other coil member 23 in the same
slot 13. A stator iron core 11 is formed by bending a
parallelepiped iron core 11A, in which a coil assembly 12 having a
plurality of coil combinations 14 combined is incorporated, so that
the respective slots 13 comes inside, making it annular, and fixing
and integrating the end portions thereof together. A stator 10 is
constructed of a coil assembly 12 and a stator iron core 11.
[0107] [Coil assembly]
[0108] First, a detailed description is given of a coil assembly
according the first embodiment with reference to FIG. 1 through
FIG. 5.
[0109] In FIG. 1, the stator 10 has a stator iron core 11 and a
coil assembly 12 incorporated therein. The stator iron core 11 is
formed to be annular and has a plurality slots 13 formed along the
inner circumferential surface at appointed pitches P. The coil
assembly 12 has an inner layer assembly 12A and an outer layer
assembly 12B coaxial incorporated in the stator iron core 11. The
inner layer assembly 12A and outer layer assembly 12B of the coil
assembly 12 is incorporated in the stator iron core 11 in a form
such that they are inserted in a plurality of slots 13. However,
for the convenience of explanation, FIG. 2 focuses on one coil
assembly 12 and shows the relationship between the coil assembly 12
and the stator iron core 11. FIG. 3 shows only one coil assembly
12.
[0110] The inner layer assembly 12A of the coil assembly 12
includes a plurality of coil combinations 14. In the first
embodiment, for example, six coil combinations 14A through 14F are
used. The respective coil combinations 14A through 14F are bent and
folded to be continuous from the left side to the right side in
FIG. 2 and FIG. 3. As shown in FIG. 5, the respective coil
combinations 14 are constructed of a combination of coil members
21, in detail, two coil members 211 and 212. The respective coil
members 21 are formed by bending one strip or band-shaped member.
The strip member is a long member of a conductive material such as
a copper material, whose section is, for example, rectangular. And
it has a width W and a thickness T. A conductive material whose
section is circular may be used.
[0111] FIG. 4 shows a coil member 21. The coil members 211 and 212
are constructed as in the coil member 21. The coil member 21 has a
plurality of the first linear portions 21A, a plurality of the
second linear portions 21B, a plurality of the first turning
portions 21C, and a plurality of the second turning portions 21D.
And, the coil member 21 is constructed by bending a strip or
band-shaped member so that they are continued from each other. A
plurality of the first linear portions 21A are disposed in parallel
to each other at a pitch NP which is equivalent to "N" times (n: a
natural number) the pitch P of the slots 13 of the stator iron core
11. A plurality of the second linear portions 21B are disposed in
parallel to each other at the same pitch NP. A plurality of the
second linear portions 21B are, respectively, in parallel to the
respective first linear portions 21A and are positioned just in the
middle of the respective first linear portions 21A adjacent to each
other.
[0112] The respective first linear portions 21A and the respective
second linear portions 21B are disposed at two circumferences
differing from each other, centering around the axial center of the
stator iron core 11. The respective first linear portions 21A are
positioned at the inner circumference of the two circumferences,
and are located at the inner layer side of the slots 13. Also, the
respective second linear portions 21B are positioned at the outer
circumference thereof and are located at the outer layer side.
These two circumferences are positioned so as to shift just by the
width W of the coil member 21 in the radial direction. As a result,
the first linear portions 21A and the second linear portions 21B
are disposed so as to shift by the width W in the radial
direction.
[0113] A plurality of the first turning portions 21C are disposed
at one end side of the respective first linear portions 21A and the
respective second linear portions 21B, that is, one end side of the
stator iron core 11. The first turning portions 21C are,
respectively, positioned between the first linear portions 21A and
the second linear portions 21B adjacent thereto at one side of the
first linear portions 21A, thereby coupling their end portions 21a
and 21b with each other at the same side. The first turning
portions 21C have inclined portions 24a and 24b respectively linked
with the end portions 21a and 21b and a turning point 24c where the
these inclined portions 24a and 24b are coupled with each
other.
[0114] A plurality of the second turning portions 21D are disposed
at the other end side of the respective first linear portions 21A
and the respective second linear portions 21B, that is, at the
other end side of the stator iron core 11. The respective second
turning portions 21D are positioned between the first linear
portions 21A and the second linear portions 21B adjacent thereto at
other side of the first liner portions 21A, and couple their end
portions 21c and 21d to each other at the same side thereof. The
second turning portions 21D have inclined portions 24d and 24e,
respectively, continued to the end portions 21c and 21d, and a
turning point 24f coupled with these inclined portions 24d and
24e.
[0115] FIG. 5 shows the construction of a coil combination 14. The
respective coil combinations 14A through 14F are constructed as in
FIG. 5. The respective coil combinations 14 are constructed of a
combination of two coil members 211 and 212. These two coil members
211 and 212 are combined such that the respective second linear
portions 21B of the coil member 212 position or overlap the outside
of the respective first linear portions 21A of the coil member 211
located on the inner circumference, and the first linear portions
21A of the coil member 212 overlap the inside of the respective
second linear portions 21B of the coil member 211 located on the
outer circumference.
[0116] The coil combinations 14 are assembled to the stator iron
core 11 in such a manner that the first linear portion 21A of the
coil member 211 and the second linear portion 21B of the coil
member 212, which overlap each other, are inserted into an
appointed slot 13 of the stator iron core 11, and the first linear
portion 21A of the coil member 212 and the second linear portion
21B of the coil member 211, which overlap each other, are inserted
into a slot 13 separated by "N" slots from the appointed slot 13.
In the appointed slot 13, the first linear portion 21A of the coil
member 211 is located at the inner layer side, and the second
linear portion 21B of the coil member 212 is located at the outer
layer side. In addition, in the slot separated from "N" slots from
the appointed slot 13, the second linear portion 21B of the coil
member 212 is located at the inner layer side, and the first linear
portion 21A of the coil member 211 is located at the outer layer
side.
[0117] The respective turning points 24c of the respective first
turning portions 21C and the respective turning points 24f of the
respective second turning points 21D are located at a position that
is extremely protruded from the stator iron core 11 at both ends of
the stator iron core 11. But, these turning points 24c and 24f are
the points of conversion of the orientation of the strip member. As
in the prior arts, the coil segments are not joined to each other
at these portions. The turning points being the points of
conversion of the orientation of the strip members do not require
any large space for joining, wherein there is an effect in which
the length of protrusion from the stator iron core 11 can be
reduced. Based thereon, the downsizing of the coil assembly 12 and
stator 10 can be achieved.
[0118] If the respective turning points 24c are constructed so as
to be shifted down in the same direction in the circumferential
direction, and concurrently, the respective turning points 24f are
shifted down in the same direction in the circumferential
direction, the length of protrusion of the turning points 24c and
24f can be further reduced, wherein the downsizing of the coil
assemblies 12 and the stator 10 can be further fostered. In this
case, the respective turning points 24c are shifted down to the
position nearer to either linear portion of the first or second
linear portions from the interim point between the first linear
portions 21A of the respective coil members 21 and the second
linear portions 21B adjacent thereto at one side thereof.
Similarly, the respective turning points 24f are shifted down to
either linear portion of the first or the second linear portions
from the interim point between the first linear portions 21A of the
respective coil members 21 and the second linear portions 21B
adjacent thereto at the other side thereof.
[0119] [Method for producing a coil assembly]
[0120] Next, a description is given of a method for producing a
coil assembly constructed as described above, with reference to the
accompanying drawings FIG. 6 through FIG. 15.
[0121] <Preparation step of a stator iron core>
[0122] First, a stator iron core 11 is prepared as a flat stator
core 11A as shown in FIG. 7. One side of the stator core 11A is
provided with a plurality of slots 13 formed at pitches P.
[0123] <Winding step of a coil assembly>
[0124] In this step, a plurality of coil combinations 14 that
constitute a coil assembly 12 are wound at the same time. In this
winding step, a pair of plate-like winding cores 25A and 25B
opposed to each other are prepared in order to simultaneously wind
a plurality of strip coil members 21, twelve coil members in this
embodiment, as shown in FIG. 8. The plate-like winding cores 25A
and 25B are provided with a plurality of projections 25a and 25b to
restrict respective strip coil members 21 on the outer surface
thereof. The respective strip coil members 21 are inserted between
the projections 25a of the plate-like winding core 25A in a state
where the coil members 21 are inclined at an appointed angle
.alpha. with respect to the extending direction of the winding
cores 25A and 25B, and are restricted and retained between the
projections 25a so that they do not move.
[0125] Next, as shown by the arrow A in FIG. 8, by turning both
plate-like winding cores 25A and 25B altogether centering around
the center axis thereof, the respective strip coil members 21 are
wound on the circumference of both plate-like winding cores 25A and
25B as shown in FIG. 9. Hereinafter, by repeating turning of both
plate-like winding cores 25A and 25B one after another, respective
strip coil members 21 are bent or folded over at the position shown
by the two-dashed line in FIG. 6(A) and are wound on the
circumference of both plate-like winding cores 25A and 25B by the
appointed number of times of winding.
[0126] Next, both plate-like winding cores 25A and 25B are moved so
as to approach each other as shown by the arrow B in FIG. 8 to
cause the restriction of the respective projections 25a and 25b and
the respective coil members 21 to be released, wherein the coil
members 21 are removed by moving them along the center of the
winding core. At this time, as shown in FIG. 9(B), the respective
coil members 21 are wound spirally so as to become rectangular when
being observed from the side thereof, so that the coil members are
provided with a plurality of the first linear portions 21A located
on the first plane 27A, a plurality of the second linear portions
21B located on the second plane 27B parallel to the first plane
27A, a plurality of the first turning portions 21C that couple the
first linear portions 21A with the second linear portions 21B
adjacent thereto at one side thereof, and a plurality of the second
turning portions 21D that couples the first linear portions 21A
with the second linear portions 21B adjacent thereto at the other
side thereof.
[0127] <Pressing step>
[0128] Next, a plurality of coil members 21 are formed by pressing.
In the pressing step, any one of the respective second linear
portions 21B and the first linear portions 21A is pressed to the
other so that the plane 27A where the first linear portions 21A
exist approaches the plane 27B where the second linear portions 21B
exist. As a result, the respective coil members 21 are deformed so
that the inner sides of both linear portions 21A and 21B exist on
almost the same surface, as shown in FIG. 9(C).
[0129] <Displacing step>
[0130] Next, the respective coil members 21 are deformed like a
tortoise shell as shown in FIG. 2 and FIG. 3, and two coil members
21 are caused to overlap each other, and the respective coil
members 21 are deformed to constitute a coil combination 14.
[0131] In the displacing step, four movable members 29A, 29B, 29C
and 29D are used as a plurality of pins. As shown in FIG. 9(D), the
movable members 29A and 29C are disposed at the left side of the
coil member 21, the movable members 29B and 29D are disposed at the
right side thereof. The movable member 29A has a plurality of pins
29a that simultaneously cause the first end portion 21a of the
first linear portion 21A of the respective coil members 21 to move,
and the movable member 29B has a plurality of pins 29b that
simultaneously cause the first end portion 21b of the second linear
portion 21B of the respective coil members to move. In addition,
the movable member 29C has a plurality of pins 29c that
simultaneously cause the second end portion 21c of the first linear
portion 21 of the respective coil members 21 to move, and the
movable member 29D has a plurality of pins 29d that simultaneously
cause the second end portion 21d of the second linear portion 21B
of the respective coil members 21 to move.
[0132] FIG. 6(B) and FIG. 10 show the movement of these movable
members 29A through 29D. In these drawings, the movable member 29A
is moved to the left side to cause the first end portion 21a to
move to the left side. The movable member 29B is moved to the right
side opposite to the movable member 29A, thereby causing the first
end portion 21b to move to the right side. Also, the movable member
29C is moved to the left side to cause the second end portion 21c
to move to the left side while the movable member 29D is moved to
the right side opposite thereto to cause the second end portion 21d
to move the right side. Resulting from the movement, the respective
coil members 21 are deformed from the state shown by a solid line
in FIG. 10 to the state shown by a dashed line therein.
[0133] As has been made clear in FIG. 10, in the respective first
linear portions 21A existing on the first plane 27A, the first end
portion 21a at the lower end thereof moves to the left while the
second end portion 21c at the upper end thereof moves to the right
side opposite thereto. In FIG. 10, the respective first linear
portions 21A will resultantly extend and exist in the vertical
direction. Similarly, in the second linear portions 21B existing on
the second plane 27B, the first end portion 21b at the lower end
thereof moves to the right while the second end portion 21d at the
upper end thereof moves to the left side. Resultantly, the second
linear portions 21B will extend and exist in the vertical
direction.
[0134] The first turning portion 21C and the second turning portion
21D are deformed along with the deformation of the abovementioned
linear portions 21A and 21B, wherein these turning points 24c and
24f accordingly protrude at the interim of the linear portions 21A
and 21B. Also, in FIG. 6(B), a position-regulating member 28 holds
and retains the first end portion at the lower side of the
respective coil member 21 and prevents the respective coil members
21 from be dispersed.
[0135] Herein, another coil member 21 shown by a one-dashed broken
line in FIG. 10 is focused on. The coil member 21 is such that,
before the displacing step, the first linear portion 21A thereof
crosses the second linear portion 21B of the coil member 21 at the
center point C in the lengthwise direction, and after the
displacing step, it overlaps the second linear portion 21B of the
coil member 21. Similarly, the second linear portion 21B of the
coil member 21 crosses the first linear portion 21A of the coil
member 21 at the center point C. As a result of the displacing
step, it will be attached to the underside of the first linear
portion 21A of the coil member 21. Thus, in the displacing step,
the respective linear portions of two coil members 21 overlap each
other, thereby forming a coil combination 14. Thus, a plurality of
coil combinations 14A through 14F are simultaneously bent and
formed.
[0136] <Inserting step>
[0137] A plurality of coil combinations 14A through 14F constructed
as described above, respectively, have such a construction as shown
in FIG. 5, and are inserted into slots 13 of the stator iron core
11 in the next inserting step. In the inserting step, the linear
portions 21A and 21B of the coil members 211 and 212 overlapping
each other are inserted into appointed slots and slots separated by
"N" slots from the appointed slots. In the appointed slots, the
first linear portion 21A of the coil member 211 is located at the
inner layer side, and the second linear portion 21B of the coil
member 212 is located at the outer layer side, and in the slots
separated by "N" slots from the appointed slots, contrarily, the
first linear portion 21A of the coil member 212 is located at the
inner layer side, and the second linear portion 21B of the coil
member 211 is located at the outer layer side. Thereafter, the
stator iron core 11A is annularly bent so that the slots 13 come to
the inner circumference. Both the end portions thereof are joined
together, and necessary wiring is carried out, wherein a stator 10
can be obtained.
[0138] Thus, according to the first embodiment, since a plurality
of strip coil members 21 are simultaneously bent to constitute a
plurality of coil combinations 14, the inserting and joining steps
of individual conductor segments, which were indispensable in the
prior arts, n be omitted. Therefore, work efficiency can be
improved, and improvements in the efficiency of mass-production can
be achieved. In addition, since there is no need to clamp coil
members by means of fixtures for joining, both the turning portions
21C and 21D can be lowered, whereby a downsizing of the coil
assemblies 12 can be achieved.
[0139] In addition, according to the method for producing rotating
electrical machinery, as shown in FIG. 11(A), since the displacing
step S3 is performed after the winding step S1 and pressing step
S2, the respective turning portions 21C and 21D can be further made
lower. Also, contrarily, as shown in FIG. 11(B), if the displacing
step S3 is performed before the pressing step S2, contact between
the respective coil members 21 can be prevented from occurring,
wherein it is possible to prevent such a situation in which the
film is destroyed due to contact, and a layer short-circuit occurs.
In addition, in FIG. 11, S4 denotes the inserting step.
[0140] Still further, according to the abovementioned producing
method, in the winding step, the respective strip coil members 21
are restricted by the respective projections 25a and 25b of the
plate-like winding cores 25A and 25B at an appointed angle a with
respect to the center axis L of the core in order to make the
band-shaped coil members spiral. However, as shown in FIG. 12, if
the strip coil members 21 are wound at an appointed angle a after
the band-shaped coil members 21 are supplied in the vertical
direction shown by the arrow B in the drawing with respect to the
center axis L of the winding core and the respective coil members
21 are restricted by the respective projections 25a and 25b, the
winding thereof on the plate-like winding cores 25A and 25B can be
made smooth, and it is possible to prevent the respective coil
members 21 from being twisted.
[0141] Also, in the construction according to the first embodiment,
the end portions of the respective coil members 21 are collected
and disposed at one end side of the slots 13. However, as shown in
FIG. 14, they may be distributed equally at one end side and the
other end side and disposed at both end sides. If so, since the
coil members 21 may be dispersed at the respective end portions,
the connection of the end portions can be facilitated.
[0142] Also, as shown at the portion A in FIG. 14, appointed
turning portions of the respective coil members are formed so as to
protrude higher than the other turning portions. And, by peeling
off the insulation film at the appointed turning portions as
necessary, lead-out portions 21E can be easily formed, wherein the
wiring workability can be improved. In addition, the lead-out
portions 21E and connections between wires are omitted in FIG.
1.
[0143] Further, it is general that the lead-out portions 21E are
connected after the respective coil members 21 are attached to the
stator iron core 11 and formed to be annular. But, as shown in FIG.
15, the neutral line of the three-phase connection and the lead-out
portions 21E that becomes the cross-over line of the respective
phase coils may be connected by TIG welding, caulking or soldering
in advance in a state where the respective coils 5 are still
linear. In this case, in comparison with the case where the coil
members 21 are formed to be annular and connected thereafter, the
degree of concentration at the coil end portions may be decreased.
Also, since the connection is carried out in a state where the
coils are still linear, the connection can be further facilitated,
and a space for inserting fixtures can be easily secured, wherein
the assembling workability can be remarkably improved.
[0144] Still further, by forming the lead-out portions of a member
having a circular cross section, peeling-off of the insulation film
at the tip end portions can be easily carried out by a machine, and
the workability can be further improved.
[0145] In addition, as shown in FIG. 6(B), the coil members 21 are
deformed to form a tortoise shell by moving the respective movable
members 29A and 29D having a plurality of pins. Actually however,
the way of forming a tortoise shell is not limited to this. That
is, for example, as shown in FIG. 13, movable members having
parallel planes 30a and 30b at both sides and a plurality of
displaceable plates 30 fitted to the orientation of the respective
linear portions 21A and 21B when deforming the coil members 21 may
be used. If so, since the respective linear portions 21A and 21B of
the coil members 21 are formed to be straight by both parallel
planes 30a and 30b of the respective blades 30, insertion thereof
into the slots 13 can be facilitated, wherein the assembling
workability and insulation ability can be remarkably improved.
[0146] Embodiment 2
[0147] FIG. 16 is a view showing a step in a method for producing a
coil assembly of rotating electrical machinery according to the
second embodiment. FIG. 17 is a view showing a step, which is
different from the step in FIG. 16, in a method for producing a
coil assembly of rotating electrical machinery according to the
second embodiment. FIG. 18 is a block diagram showing steps in a
method for producing a coil assembly of rotating electrical
machinery according to the second embodiment. FIG. 19 is a
perspective view showing the appearance a stator of an alternate
current generator for vehicles, which is different from FIG. 1 in
which coil members in the first and second embodiments are applied.
FIG. 20 is a view showing a method that is different from the
method in FIG. 16 showing the steps of producing a coil assembly in
the second embodiment of the invention.
[0148] A coil assembly of rotating electrical machinery secured by
the second embodiment is similar to that in which a coil assembly
12 according to the first embodiment described above is disposed.
Therefore, no further illustration is provided. However, since the
production method differs from that of the first embodiment, a
description is given of the production method with reference to the
drawings.
[0149] First, by bending a plurality of strip coil members 21 on
one plate, a plurality of linear portions 33 disposed so as to
shift by an appointed pitch P, and a plurality of inclined portions
34 connecting between the plurality of linear portions 33 are
formed. The respective inclined portions 34 are inclined at an
appointed angle a with respect to the respective linear portions
34.
[0150] Next, at bisectors G of the respective inclined portions 34,
which are shown by a two-dashed broken line in FIG. 16, the
respective coil members 21 are bent. The respective bisectors G are
located at the positions where the respective inclined portions 34
are divided into an upper half portion 34a and a lower half portion
34b, wherein the coil members 21 are bent at the bisectors G so
that the lower half portions 34b cross and overlap the respective
coil members 21 of the upper half portions 34a at an angle .alpha..
The bending work is carried out from the inclined portion 34
located extremely upward in FIG. 16 one after another. As a result,
as in the first embodiment, the first linear portions 21A and the
second linear portions 21B are formed, corresponding to the
respective linear portions 33, and the first turning portions 21C
and the second turning portions 21D are formed, corresponding to
the respective inclined portions 34. A plurality of tortoise
shell-like coil combinations 14 are simultaneously produced as in
FIG. 5. In the bending step, the second linear portion 21B of
another coil member is piled up on the first linear portion 21A of
one coil member, and the first linear portion 21A of another coil
member 1 is attached below the second linear portion 21B of one
coil member, wherein the coil combination 14 having the same
construction as that in FIG. 5 is constituted.
[0151] And, as in the first embodiment, the first linear portion
21A of the coil members 211 overlapping each other and the second
linear portion 21B of the coil members 212 are inserted into
appointed slots 13, and the second linear portions 21B of the coil
members 211 overlapping each other and the first linear portions
21A of the coil members 212 are inserted into slots 13 separated by
"N" slots from the appointed slots 13.
[0152] Thus, according to the second embodiment, since a plurality
of coil combinations 14 can be obtained by carrying out the folding
step S6 to fold up a plurality of strip coil members 21 after the
bending step S5 to bend them on a plane as shown in FIG. 18, steps
for inserting conductor segments and joining the same, which are
necessary in the prior arts, can be omitted as in the first
embodiment described above. Therefore, the work efficiency can be
improved, and the mass productivity can also be improved. Further,
no clamping by means of fixtures is required for joining together,
wherein both the turning portions 21C and 21D can be made lower,
and the coil assemblies 12 can be downsized. In addition, in FIG.
18, Step S4 is the same inserting step as in FIG. 11.
[0153] Furthermore, in the first and second embodiments described
above, a description was given of the construction of a stator 10
in which the coil assemblies 12A and 12B are piled up in two layers
and inserted into slots. But, the construction is not limited to
the above construction. For example, a stator 10 may be constructed
by using coil assemblies 12 consisting of three-layered coil
assemblies 12A, 12B and 12C as shown in FIG. 19. In this case,
effects which are similar to those in the first and second
embodiments can be brought about.
[0154] Still further, the second linear portions 33A that are
parallel to the linear portions 33 may be formed, as shown in FIG.
20, halfway along the inclined portions 34 shown in FIG. 16. By the
second linear portions 33A, turning portions by which lead-out
portions, etc., can be easily formed may be formed, wherein the
wiring workability can be improved.
[0155] Embodiment 3
[0156] FIG. 21 is a perspective view showing the appearance of a
stator of an alternate current generator for vehicles, to which a
coil according to the third embodiment of the invention is applied,
FIG. 22 is a perspective view explaining the profile of the first
coil in FIG. 21, FIG. 23 is a perspective view explaining an array
profile of the first coil member in FIG. 21, FIG. 24 is a
perspective view explaining the profile of the second coil member
in FIG. 21, FIG. 25 is a perspective view explaining an array
profile of the second coil member in FIG. 21, and FIG. 26 is a
perspective view explaining an array of combinations of coil
combinations in FIG. 21.
[0157] In the drawings, parts which are identical to those of the
first embodiment are given the same reference numbers, and
overlapping description thereof is omitted. The first coil members
35 is formed of one strip conductor having a width W and a
thickness T as in the coil member 21 in the first embodiment
described above. And, the first coil members 35 are formed of the
first linear portions 35A and the second linear portions 35B, which
are alternately disposed at the inner layer side and the outer
layer side of the slots 13, shifting by the width W in the
direction of lamination at an appointed pitch P as shown in FIG.
22, and the first turning portions 35C and the second turning
portions 35D that connect both the linear portions 35A and 35B
outward of one end side and the other end side of the slots 13 in
the lengthwise direction.
[0158] The second coil member 36 is formed of one strip conductor
having a width W and a thickness T. The second coil member 36
consists of the first linear portions 36A and the second linear
portions 36B, which are alternately disposed at the inner layer
side and the outer layer side of the slots 13, leaving an interval
equivalent to the dimension 2W, which is two times the width W, in
the direction of lamination at an appointed pitch P as shown in
FIG. 24, and the first turning portions 36C and the second turning
portions 36D that connect both the linear portions 36A and 36B
outward of one end side and the other end side of the slots 13 in
the lengthwise direction.
[0159] And, two of the first coil members 35 formed as shown in
FIG. 22 are combined to constitute the first coil combination 37.
Two coil members to be combined are shown with reference numbers
351 and 352. The coil combination 37 is combined so that the first
linear portion 35A of the coil member 351 and the second linear
portion 35B of the coil member 352 are piled up as shown in FIG.
23. On the other hand, two of the second coil members 36 formed as
shown in FIG. 24 are combined to constitute the second coil
combination 38. The two coil members to be combined are shown with
reference numbers 361 and 362. The coil combination 38 is disposed
so that the first linear portion 36A of the coil member 361 opposes
the second linear portion 36B of he coil member 362 via a space 2W
as shown in FIG. 25, and the second linear portion 36B of the coil
member 361 opposes the first linear portion 36A of the coil member
362 via a space 2W.
[0160] Subsequently, the first coil combination 37 and the second
coil combination 38 are combined with each other as shown in FIG.
26. In FIG. 26, the first coil combination 37 is combined with the
second coil combination so that the overlapping section of the two
linear portions 35A and 35B of the first coil combination 37 is
inserted into the space 2W in the second coil combination 38. In
FIG. 26, at the first portion 39A where four linear portions 35A,
35B 36A and 36B are piled up, the first linear portion 36A of the
coil member 361 is located on the first layer at the extremely
inner side, the first linear portion 35A of the coil member 351 is
located on the second layer of the outer circumference thereof, the
second linear portion 35B of the coil member 352 is located on the
third layer of the further outer circumference thereof, and the
second linear portion 36B of the coil member 362 is located on the
fourth layer which is the extremely outer circumference. At another
second portion 39B where the four linear portions are piled up, the
first linear portion 36A of the coil member 362 is located on the
first layer which is the extremely inner side, the first linear
portion 35A of the coil member 352 is located on the second layer
of the outer circumference thereof, the second linear portion 35B
of the coil member 351 is located on the third layer of the further
outer circumference thereof, and the second linear portion 36B of
the coil member 361 is located on the fourth layer which is the
extremely outer side.
[0161] Next, the coil combinations 37 and 38 are incorporated in
the stator iron core 11A so that the first portion 39A in FIG. 26
is inserted into appointed slots 13, and the second portion 39B
therein is inserted into slots 13 separated by "N" slots from the
appointed slots 13. The other coil combinations are inserted into
the other slots 13. After internal wiring necessary for these coil
combinations is provided, the stator iron core 11A is annularly
bent to secure the stator 10.
[0162] Coil members 351 and 352 in the third embodiment constructed
as described above are formed by a method that is similar to that
for the coil members 211 and 212 in the first and second
embodiments. Also, since coils 361 and 362 are formed by shifting
the first and second linear portions 36A and 36B opposed thereto by
the internal 2W therebetween, a description of the production
method is omitted.
[0163] Thus, according to the third embodiment, since the first and
second coil combinations 37 and 38 that are formed by the same
production method as that in the first and second embodiments are
combined, the efficiency of mass-production and downsizing are
enabled as in the first and second embodiments.
[0164] In addition, in each of the first through the third
embodiments, the insulation thereof can be prevented from being
lowered by using a strip coil member having a rectangular
cross-section, and the occupancy ratio of the coil members in a
slot 13 can be improved.
[0165] However, the cross-section of the coil member is not limited
to this. For example, a strip coil member having a circular
cross-section may be used instead, wherein if such a strip coil
member having a circular cross-section is used, the following
effects will be further enabled.
[0166] That is, it will become easy for fixtures to be mounted in
the winding step, and there will be no worry about twisting of the
strip member when winding a coil member. Therefore, the efficiency
of production can be further improved. In addition, it will become
possible to suppress the breakage of insulation films due to
bending of the tip ends of the turning portions in the displacing
step, wherein the efficiency of insertion into the stator iron
cores 11 and 11A is improved to reduce the breakage of the films.
Still further, breakage of the films, which results from mutual
contact of the respective coil members when making the stator iron
core 11A annular by bending, can be reduced. Breakage of the films
due to mutual contact of coil members in the slots 13 of the stator
iron core 11 or between the coil members and the inner wall surface
of the slots 13 can be reduced, thereby improving the insulation
property.
[0167] In addition, in the step of peeling off films at the end
portions of the coil members, mechanical peeling can be
facilitated, thereby improving the workability. Since cooling
airflow passing through the coil end portions can be smoothened,
and airflow noise can be reduced, wherein the reliability can be
improved.
[0168] Still further, although not explained in the first through
the third embodiments, the case of the coil members 35 and 36 shown
in FIG. 26 is taken for instance, wherein if the respective first
turning portions 35C, 36C and the second turning portions 35D and
36D are inclined in the same side in the circumferential direction,
the height of the coil ends can be made lower, and downsizing can
be achieved. At the same time, ventilation resistance at the coil
ends can be reduced, wherein the cooling property can be further
improved.
* * * * *