JPH10117455A - Rotor in dynamo electric machine and manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve withstanding strength against centrifugal force without increase in the number of parts or cost. SOLUTION: An armature coil includes coil separating parts 5 with the same number as that of through-holes 4 in an armature core 3, and the other coil separating part 6. These separating parts 5 and 6 have upper coil members 5a and 6a inserted in an outer circumferential side and lower coil members 5d and 6a inserted in an inner circumferential side. The upper coil member 5a and a lower coil member 5d of the coil separating part 5 are inserted from one axial end of the armature core 3 into each given through-hole 4, while the upper and lower coil members 6a and 6d are inserted from the other axial end to each given through-hole 4. Then, the edges of upper coil members 5a and 6a are connected to the edges of lower coil members 5d and 6d.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a rotor for a rotating electric machine.

[0002]

2. Description of the Related Art As a prior art, for example, Japanese Unexamined Patent Publication No. Sho 60-2
No. 26755 discloses a method of manufacturing a rotor. According to this manufacturing method, after a conductor having a first linear portion and a second direct portion is inserted into a slot of an armature core from the axial direction side, a first linear portion and a second linear portion drawn out from different slots are inserted. A straight section is connected to each segment of the commutator. However, in order to connect the first straight portion and the second straight portion on each segment of the commutator, a portion projecting from a slot of the first straight portion and the second straight portion must be connected to an axis of the armature core. A wire twisting step is required to bend toward the end face in the direction and to incline at a predetermined angle also in the circumferential direction of the armature core. For this reason, there has been a problem that unnecessary deformation such as twisting of the conductive wire occurs.

Accordingly, the present applicant has filed Japanese Patent Application No. Hei 7-3269.
No. 83 proposed a method of manufacturing a rotor that does not require a so-called "wire twisting step". This prior application discloses an upper coil having a pair of upper coil ends connected to both ends of an upper coil side at a substantially right angle to the upper coil side and inclined at a predetermined angle in a circumferential direction around the upper coil side. And a pair of lower coil ends connected to the both ends of the lower coil side at a substantially right angle to the lower coil side and inclined at a predetermined angle in the circumferential direction around the lower coil side. After the lower coil and the two coils are sequentially inserted from the outside in the radial direction into the slots of the armature core,
The connection part of the upper coil end and the connection part of the lower coil end are joined. According to this manufacturing method, the upper coil and the lower coil are each formed of an integral part obtained by bending a conductor, and the two connecting portions naturally overlap with each other during the assembly process. Not required. Accordingly, unnecessary deformation such as coil twisting does not occur, and the incorporation into the armature can be performed accurately and easily. Therefore, a highly accurate and robust armature coil can be provided at low cost.

[0004]

However, in the rotor obtained by the manufacturing method of the prior application, the connecting portion of the upper coil end and the connecting portion of the lower coil end are connected at both axial ends of the armature core. In the connection structure, since the connection portion itself is exposed outside the armature core, there is a problem in centrifugal strength. In contrast,
A method of securing a centrifugal strength by attaching a cover to the connection portion is also described, but in this case, there is a problem that the cost increases due to an increase in the number of parts. The present invention has been made based on the above circumstances, and an object of the present invention is to provide a method of manufacturing a rotor of a rotating electric machine with improved centrifugal strength without increasing costs due to an increase in the number of parts. It is in.

[0005]

According to the first and second aspects of the present invention, the end faces of one upper coil piece and the other upper coil piece inserted on the radially outer side in the through hole of the armature core. The end faces of one lower coil piece and the other lower coil piece inserted on the radially inner peripheral side in the through-hole are electrically connected to each other in the through-hole. This allows
Even if the rotor rotates and centrifugal force is applied to the armature coil,
Because the joint between the end faces of each coil piece is in the through hole,
The joint can be supported with sufficient holding force against centrifugal force, and a rotor having excellent centrifugal strength can be provided.

According to the third and fourth aspects of the present invention, the end faces of one upper coil piece and the other upper coil piece, which are inserted radially inward in the slot of the armature core, and the inner diameter of the slot. The end faces of one lower coil piece and the other lower coil piece inserted on the inner circumferential side in the direction are electrically connected to each other in the slot, and the joint is provided at the opening end of the slot. Is pressed from the outer peripheral side.
Thus, even if the rotor rotates and centrifugal force is applied to the armature coil, the joint can be supported with sufficient holding force against centrifugal force, and a rotor having excellent centrifugal strength can be provided.

[0007]

Next, a method for manufacturing a rotor of a rotating electric machine according to the present invention will be described with reference to the drawings. (First Embodiment) FIG. 1A is a front view of the rotor on the side opposite to the commutator, FIG. 1B is a cross-sectional view of the rotor, and FIG. 1C is a front view of the rotor on the side of the commutator. The rotor 1 of the present embodiment is used, for example, as an armature of a starter for starting an engine, and as shown in FIG.
(See FIG. 2), an armature coil (described later), and the like, and a part of the armature coil is used as a commutator (no symbol).

[0008] The armature core 3 is formed by laminating a plurality of thin steel plates punched into a disk shape by a press machine.
As shown in (b), the shaft 2 is fitted and fixed to a serration (vertical groove) 2 a formed on the outer periphery of the shaft 2. The armature core 3 is provided with a through-hole 4 (see FIG. 2) penetrating the armature core 3 in the axial direction. The through hole 4
Are provided at predetermined positions in the circumferential direction at a position closer to the outer periphery in the radial direction of the armature core 3 and are provided in a predetermined number.

The armature coil is composed of one coil divisional body 5 and the other coil divisional body 6 in the same number as the number of through holes 4, and each is formed of a material having excellent conductivity (for example, copper). As shown in FIG. 3, one of the coil splitters 5 includes an upper coil piece 5a inserted into the through hole 4 of the armature core 3, and an end face of the armature core 3 from one end of the upper coil piece 5a. The upper coil end 5b extending to the axial center side along the axis, the lower coil end extending from the axial end of the upper coil end 5b to the outer peripheral side along the end surface of the armature core 3 Part 5c and a lower coil piece 5d inserted into the through hole 4 of the armature core 3 from the outer peripheral end of the lower coil end part 5c
Consists of

The upper coil piece 5a is inserted into the radially outer peripheral side in the through hole 4 and has a length such that its tip reaches the axial center in the through hole 4 (see FIG. 1B). . As shown in FIG. 1A, the position of the outer coil end 5b of the upper coil end 5b is shifted from the normal (radius) of the armature core 3 in the circumferential direction. , From the outer peripheral end to the axial center end. As shown in FIG. 1A, the position of the lower end 5c is shifted in the circumferential direction with respect to the normal (radius) of the armature core 3 between the axial end and the outer end. It is provided in a shape slightly curved from the axial end to the outer peripheral end (however, curved to the side opposite to the upper coil end 5b). The lower coil piece 5d is provided with the through hole 4 (however, the through hole 4 into which the upper coil piece 5a is inserted).
The through-hole 4) is inserted into a radially inner circumferential side of the through-hole 4), and has a length such that the tip reaches the axial center of the through-hole 4 (see FIG. 1B).

As shown in FIG. 3, the other coil split body 6 is provided with an upper coil piece 6a inserted into the through hole 4 of the armature core 3, and the other end of the upper coil piece 6a An upper coil end 6b extending toward the axial center along the end face of the upper armature 3 and a lower end extending from the axial end of the upper coil end 6b to the outer peripheral side along the end face of the armature core 3. The lower coil piece 6d inserted into the through hole 4 of the armature core 3 from the outer coil end 6c and the outer peripheral end of the lower coil end 6c.
Consists of

The upper coil piece 6a is inserted into the radially outer peripheral side in the through hole 4 and has a length such that the tip reaches the axial center in the through hole 4 (see FIG. 1B). . As shown in FIG. 1 (c), the position of the outer peripheral end and the axial end of the upper coil end 6b are shifted in the circumferential direction with respect to the normal line (radius) of the armature core 3. , From the outer peripheral end to the axial center end. The upper coil end 6b is used as one commutator piece constituting a commutator. As shown in FIG. 1C, the lower coil end 6c is displaced in the circumferential direction with respect to the normal (radius) of the armature core 3 between the axial end and the outer end. It is provided in a shape slightly curved from the axial end to the outer peripheral end (however, curved to the opposite side to the upper coil end 6b). The lower coil piece 6d is inserted radially inside the through hole 4 (however, a through hole 4 different from the through hole 4 into which the upper coil piece 6a is inserted), and the tip is a shaft inside the through hole 4. The length is set to reach the center in the direction (see FIG. 1B).

Next, a method of assembling the armature coil will be described. First, the same number of coil split bodies 5 and the other coil split bodies 6 as the number of through holes 4 of the armature core 3 are prepared. Then, the upper coil piece 5 of one coil divided body 5
a and the lower coil piece 5d are respectively inserted into the predetermined through-hole 4 from one axial end of the armature core 3, and the upper coil piece 6a and the lower coil piece 6d of the other coil split body 6 are respectively armatured. A predetermined through hole 4 from the other axial end of the core 3
Insert into. At this time, each coil segment 5a, 5d of one coil segment 5 and each coil segment 6 of the other coil segment 6
a and 6d are inserted until the end faces come into contact with each other. Subsequently, the end faces of the upper coil piece 5a of the one coil split body 5 and the upper coil piece 6a of the other coil split body 6 inserted into the same through hole 4 and the lower side of the one coil split body 5 The end faces of the coil piece 5d and the lower coil piece 6d of the other coil split body 6 are electrically joined.

As a joining method, one coil segment 5 and the other coil segment 6 are pressed in the axial direction while energizing the coil segments 5a, 5a,
a method of welding the end faces of d and 6a, 6d to each other, a method of applying ultrasonic waves to one of the coil split bodies 5 and the other coil split body 6 while pressing them in the axial direction, and joining them by brazing. Method, one coil piece 5a, 5d and the other coil piece 6a, 6
(e.g., by providing a protrusion on the end face of one of the coil pieces 5a, 5d and providing a recess on the end face of the other coil piece 6a, 6d). Is pressed in the axial direction to be fitted).

The upper coil pieces 5a and 6a and the lower coil pieces 5d and 6d and the inner wall surface of the through hole 4 and the upper coil pieces 5a and 6a and the lower coil pieces 5d and 6d have
An insulator is interposed between them to ensure mutual insulation. The insulator 7 is also provided between the axial end surface of the armature core 3 and the lower coil ends 5c, 6c, and between the lower coil ends 5c, 6c and the upper coil ends 5b, 6b. , 8 (see FIG. 1 (b)) to ensure the mutual insulation. Alternatively, an insulator (for example, Teflon, ceramic, or the like) may be applied to the entire circumference of the one coil split body 5 and the other coil split body 6, and assembled to the armature core 3. However, the other coil segment 6
It is necessary to secure the commutator surface by shaving the insulator applied only to the outer end surface of the upper coil end 6b.

(Effects of the present embodiment) In the present embodiment, the upper coil piece 5a of one coil split body 5 and the upper coil piece 6a of the other coil split body 6, which are inserted into the same through hole 4,
The lower coil piece 5d of the one coil split body 5 and the lower coil piece 6d of the other coil split body 6 are joined with their end faces abutting in the through hole 4, respectively. For this reason,
Even if the rotor 1 rotates and a centrifugal force is applied to the armature coil, one coil piece 5a, 5d and the other coil piece 6a,
Since the joint between the end faces of the joint 6d is located in the through-hole 4, there is no need to provide a cover as in the related art, and the joint can be supported with sufficient holding force against centrifugal force. As a result, the rotor 1 excellent in centrifugal strength can be provided without increasing the cost due to an increase in the number of parts. In the present embodiment, the upper coil pieces 5a and 6a and the lower coil pieces 5d and 6d are inserted into one through hole 4, but the through hole 4 into which the upper coil pieces 5a and 6a are inserted and the lower coil piece are inserted. Piece 5d,
The through-hole 4 for inserting 6d may be provided independently.

FIG. 4 is a perspective view of the armature core 3 (second embodiment). In the present embodiment, as shown in FIG.
Has a predetermined number of slots 9 on its outer periphery, and a claw 10 having a substantially V-shaped cross section is provided between adjacent slots 9 in the circumferential direction. The claw 10 is provided over the entire length of the slot 9 in the axial direction. As in the first embodiment, the armature coil has one coil segment 5 (upper coil piece 5).
a, upper coil end 5b, lower coil end 5c, lower coil piece 5d) and the other coil segment 6 (upper coil piece 6).
a, an upper coil end 6b, a lower coil end 6c, and a lower coil piece 6d).

In this armature coil, the upper coil piece 5a and the lower coil piece 5d of one coil split body 5 are inserted into predetermined slots 9 from one axial end of the armature core 3, respectively. After inserting the upper coil piece 6a and the lower coil piece 6d of the split body 6 from the other axial end of the armature core 3 into predetermined slots 9, respectively,
Upper coil piece 5 of one coil split body 5 inserted in
a and the end faces of the lower coil piece 5d of one coil split body 5 and the lower coil piece 6d of the other coil split body 6 are electrically connected to each other. It is formed by joining. Note that the upper coil piece 5a and the lower coil piece 5d of one coil split body 5 and the upper coil piece 6a and the lower coil piece 6d of the other coil split body 6
May be inserted not only from the axial side of the armature core 3 but also from the radially outer peripheral side of the armature core 3.

Subsequently, each coil segment 5a, 5d of one coil segment 5 and each coil segment 6 of the other coil segment 6
After joining the end surfaces a and 6d, the claw 10 provided between the slots 9 adjacent in the circumferential direction is bent toward the slot 9 to close the opening edge of the slot 9 (see FIG. 5).
As a result, each coil piece 5a inserted into the slot 9,
Since 5d, 6a, and 6d are pressed from the outer peripheral side by the bent claw 10, the coil pieces 5a, 5d, 6a, and 6d can be prevented from jumping out of the slot 9 due to centrifugal force applied during rotation. As a result, the joints of the coil pieces 5a, 5d and 6a, 6d joined in the slot 9 can be supported with a sufficient holding force against centrifugal force, so that the rotor 1 having excellent centrifugal resistance is provided. Can be provided. In the second embodiment, the upper coil pieces 5a, 6a and the lower coil pieces 5d, 6d are inserted into one slot 9, but the slots 9 into which the upper coil pieces 5a, 6a are inserted.
And the through holes 4 into which the lower coil pieces 5d and 6d are inserted may be provided independently.

[Brief description of the drawings]

FIG. 1 is a front view of a rotor on an anti-commutator side (a), a sectional view of a rotor (b), and a front view of a rotor on a commutator side (c).

FIGS. 2A and 2B are an axial half-front view of the armature core and a cross-sectional view of the armature core.

FIG. 3 is a perspective view of one coil divided body and the other coil divided body forming an armature coil.

FIG. 4 is a perspective view of an armature core (second embodiment).

FIG. 5 is a cross-sectional view of the vicinity of a slot provided in an armature core (second embodiment).

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 rotor 3 armature core 4 through hole 5 one coil split body 5a one upper coil piece 5b one upper coil end (one connection piece) 5c one lower coil end (one connection piece) 5d One lower coil piece 6 The other coil split body 6a The other upper coil piece 6b The other upper coil end (the other connection piece) 6c The other lower coil end (the other connection piece) 6d The other lower side Coil piece 9 Slot 10 Claw

Claims (4)

[Claims] 1. A rotor for a rotating electric machine, comprising: an armature core having a predetermined number of through holes penetrating in an axial direction; and an armature coil mounted on the armature core, wherein the armature coil One upper coil piece inserted into the radially outer peripheral side inside the through-hole on one side in the axial direction of the armature core, and the radially inner peripheral side in the through-hole on one axial side of the armature core in the axial direction. One end of the upper coil piece and the end of the lower coil piece taken out from the different through-holes at the one end in the axial direction of the armature core. One coil split body comprising one connection piece to be connected; the other upper coil piece inserted into the radially outer peripheral side in the through hole on the other axial side of the armature core; the shaft of the armature core On the other side in the radial direction inside the through hole The other lower coil piece, and the other connecting the end of the upper coil piece and the end of the lower coil piece taken out from the different through holes at the other axial end of the armature core. The other coil divided body comprising a connecting piece, the one coil divided body and the other coil divided body,
End faces of the one upper coil piece and the other upper coil piece, and end faces of the one lower coil piece and the other lower coil piece are electrically connected in the through hole, respectively. A rotor for a rotating electric machine, characterized by being characterized in that: 2. The rotor according to claim 1, wherein the armature coil includes the same number of the one coil divided bodies and the other coil divided bodies as the number of the through holes, each of the one coil. The one upper coil piece and the one lower coil piece of the split body are inserted into the through hole from one axial end of the armature core, and the other upper coil of the other coil split body is inserted. After inserting a piece and the other lower coil piece into the through hole from the other axial end of the armature core, the end faces of the one upper coil piece and the other upper coil piece, and A method for manufacturing a rotor, wherein end faces of one lower coil piece and the other lower coil piece are electrically connected to each other in the through hole. 3. A rotor of a rotary electric machine having an armature core having a predetermined number of slots on the outer periphery and having a claw at an open end of the slot, and an armature coil mounted on the armature core. In the armature coil, one upper coil piece inserted on one side in the axial direction of the armature core and radially outer side in the slot, the slot on one side in the axial direction of the armature core One lower coil piece inserted on the radially inner side of the inside, and the end of the upper coil piece and the lower coil piece taken out from different slots at one axial end of the armature core. One coil segment comprising one connecting piece that connects the end of the armature core; and the other upper coil piece inserted into the slot on the other side in the axial direction of the armature core and radially outside in the slot. Axial direction of child core The other lower coil piece inserted on the radially inner peripheral side in the slot on one side, and the end of the upper coil piece taken out from the different slot at the other axial end of the armature core And the other coil divided body composed of the other connection piece that connects the end of the lower coil piece, wherein the one coil divided body and the other coil divided body are:
The end faces of the one upper coil piece and the other upper coil piece, and the end faces of the one lower coil piece and the other lower coil piece are electrically connected to each other in the slot, respectively. A rotor for a rotary electric machine, wherein a joint is pressed from a radially outer peripheral side of the armature core by a claw provided at an opening end of the slot. 4. The rotor according to claim 3, wherein the armature coil includes the same number of the one coil divided bodies and the other coil divided bodies as the number of the slots.
Each of the one upper coil piece and the one lower coil piece of the one coil split body is inserted into the slot from one axial end of the armature core, and The other upper coil piece and the other lower coil piece are inserted into the slot from the other axial end of the armature core, and the end faces of the one upper coil piece and the other upper coil piece are connected to each other. After the end faces of the one lower coil piece and the other lower coil piece are electrically connected to each other in the slot, the joint is provided at the open end of the slot. 4. The method for manufacturing a rotor according to claim 3, wherein the claw is bent and pressed from a radially outer side of the armature core.