Means for holding a coil for an electromechanical device for converting electrical energy and mechanical energy

Abstract

A pair of retaining means 30 designed for holding a coil 10 which is to be mounted in slots 22 between several teeth 21 of a core 20 for an electromechanical device that converts electrical and mechanical energy, each of the retaining means 30 having: at least two base plates 32 which are openably coupled at one end; an outlet 31 formed between the other ends of the base plates 32, wherein the outlet 31 is suitable for being aligned with an axial opening 23 of a slot 22; and a holding chamber 32a, which can be opened at the outlet 31 and which, when the base plates 32 close, holds windings 10A, which form a first bearing section 11a and a second bearing section 11b of the coil 10, if the alignment of the windings 10A is maintained, wherein one holding means 30 of the pair of holding means 30 holds the first bearing section 11a of the coil 10 and the other holding means 30 of the pair of holding means 30 holds the second bearing section 11b of the coil 10, and wherein when the coil 10 is mounted in the slots 22, each holding space 32a is connected to an interior of the slot 22 through the axial opening via the holding means 30.

Description

BACKGROUND OF THE INVENTIONField of the invention

[0001] The present invention relates to a means for holding a coil for electromechanical devices such as motors and generators that convert electrical energy and mechanical energy. Description of related technology

[0002] The process of manufacturing coils for electromechanical devices that convert electrical and mechanical energy—where a coil is wound around several teeth of a core enclosing a rotor—is very difficult. This is because the space (slot) between each tooth is very narrow and deep. Therefore, excellent skills are required for winding the number of coils necessary to achieve a sufficient magnetic flux density.

[0003] Typical automatable methods capable of winding coils at a high density around a core of an electromechanical device are known. For example, JP H11-312621 A proposes a "concentrated winding" method in which coils are wound concentratedly around each tooth, and JP 2009-195005 A proposes a "distributed winding" method in which coils are wound around multiple slots, and coils that are in or out of phase with each other are overlapped at the coil ends.

[0004] As in Fig. 25 (a), the coils disclosed in JP H11 - 312 621 A are individually wound around each of the plurality of cores 72 separated into multiple sections so that one coil is wound around one tooth 104 of each core 72. Fig. Figure 25 (b) shows a single such coil in which a rectangular wire is wound in three layers. The cores 72 around which the coils are wound are arranged in a circle and integrated to form a stator, as in Fig. 25 (a).

[0005] The coil winding device proposed in JP H11-312621 A uses concentrated winding, which allows the coil ends to be smaller compared to distributed winding, as described below, which is advantageous for the compact design of the electromechanical device and the improvement of its efficiency. On the other hand, as described in Fig. 25 (a), there must always be a section in each slot where there is no coil, since the T-shaped cores 72 must be formed integrally with each other. Also, if the rectangular wire windings are to be Fig. 25 (b), the rectangular wire is bent at right angles at the corners of the coil, causing deformation of the bent portions of the rectangular wire. Furthermore, the winding device proposed in JP H11-312621 A has a configuration in which rollers are in contact with the rectangular wires as they reciprocate with respect to a rotating bobbin, meaning that the device is limited to rectangular wires and cannot be applied to round wires with a circular cross-section.

[0006] The coils disclosed in JP 2009 - 195 005 A, which are wound in a distributed manner, are stored in the slots of the core, as in Fig. 26 (a). This core consists, for example, of 48 slots 411 provided with teeth 414 therebetween. The teeth 414 are integrated into the cylindrical core back 430, in which the coils are mounted between the teeth 414 (in the slots), each coil being wound around and over several teeth 414.

[0007] A single such coil is in Fig. 26 (b) and consists of a rectangular wire wound in several layers. As shown in Fig. 20: "The two coils formed by α-winding a conductor wire whose cross-section is rectangular are continuously manufactured. The two continuously loop-wound coils were formed by molding the two continuously α-wound coils into an oval coin shape, and the coil was formed by inserting the coil into a slot of the stator. The two continuously α-wound coils were formed such that the center of a corner wire was pressed against the winding frame, and two rollers abutted against the corner wire attached to the winding frame, so that they are mutually reversely rotated." (From the abstract of JP 2009 - 195 005 A)

[0008] The coils shown in JP 2009 - 195 005 A, as in Fig. 26 (b), are mounted in several grooves of an inner clamping device 36, as shown in Fig. 27, which is inserted into the core, after which the coils are pressed into the corresponding slots. The clamping device 36 is removed from the core after the coils have been stored, resulting in a core equipped with coils, as shown in Fig. 26 (a).

[0009] For example, the coils can be inserted using a clamping device without subsequently removing the clamping device. DE 33 09 051 A1 discloses a prefabricated winding for an electric linear motor, which is held together by half-shells and thus inserted into slots provided for the winding.

[0010] In the core equipped with the coil proposed in JP 2009 - 195 005 A, as shown in Fig. As shown in Figure 26 (a), the "coil end portions" protrude substantially upward and downward from the "slot portion (core portion)." Judging from this appearance, significant copper loss is likely occurring at the coil end portions. The significant protrusion of the coil end portions from the slot (core) portion not only means that the copper loss, i.e., the power loss, is high, but also that a large amount of space is required to store this type of core.

[0011] Incidentally, regarding coils for electromechanical devices, the coils themselves, the teeth around which the coils are wound, and the slots in which the coils are mounted must generally be uniform and equally spaced from each other. This is necessary because the rotation of the electric motor must be smooth to achieve stable functionality by causing each coil to generate or cut off a constant magnetic flux density per unit time.

[0012] While the best way to increase energy density is to fill each slot with as many conductor wires as possible, winding the conductor wires (coils) without gaps in the narrow, deep slots is not as easy as Fig. 25 (a) is evident.

[0013] Additionally, when filling each slot with as many conductor wires as possible, insulating adjacent coils becomes necessary. DE 10 2006 003 498 A1 provides for subsequently installed interphase insulation, which is attached to the winding support with a connecting section.

[0014] Furthermore, for the automated mass production of this type of coil, cores in which the coils are mounted, and electromechanical devices incorporating these components, the following problems must be solved simultaneously and comprehensively.

[0015] Regarding coils in general, it is true that in a case where a conventional coil is mounted across two slots, the windings will be in the same position of the coil in the same position of both slots. Since the slots, both on the rotor side and the core side, are formed radially with respect to the center of the armature, the dimensions of their inner sides and their outer sides differ. Thus, when a conventional coil is mounted within two slots, the windings are mounted in the same position, causing uneven inductance in the inner and outer windings (wires) with respect to a magnet provided outside the armature, resulting in an overall decrease in the coil's efficiency.The reason for this is that if an identical voltage is applied to the wires simultaneously, a larger current will flow in the wires at lower inductance, and this uneven inductance will tend to reduce the overall efficiency of the coil. Therefore, there is a need for a coil designed to compensate for the uneven inductance in the windings so that the coil's efficiency can be improved.

[0016] For this purpose, an anchor proposed in JP 5 394 058 B2 has the following configuration, as described in claim 1 thereof: "Armature for an electric motor, comprising: a core having a plurality of slots and a plurality of teeth formed between the slots; and a winding of a plurality of bundled wires, the winding having a plurality of coil parts and a plurality of connecting portions, the coil parts being inserted into the slots and around and over the plurality of teeth by means of distributed winding, the connecting portions connecting the coil parts to each other, the winding having a twisted shape in the connecting portions." This design addressed the problem of conventional armatures that uneven inductance in each wire is the cause of lower coil efficiency and reduced motor efficiency, and provided improvements for the purpose of providing an armature and electric motor that can improve motor efficiency.

[0017] Furthermore, paragraph

[0013] of JP 5 394 058 B2 discloses the following: "The winding comprises coil parts and connecting portions. The coil parts are inserted into the slots and wound around and over the plurality of teeth by means of distributed winding. The connecting portions connect the coil parts to each other. The winding has a twisted shape in the connecting portion." Thus, based on claim 1 of JP 5 394 058 B2, it was found that the anchor proposed therein is characterized in that: • the coils are wound several times around and over the multiple teeth by means of distributed winding • the coils are connected to each other by means of the connecting sections • the windings in the connecting sections have a twisted shape.

[0018] As mentioned above, these "connecting portions" disclosed in JP 5 394 058 B2 serve to "connect the coil parts to each other" and thus correspond to the "connecting lines that electrically connect the coils to each other" of the invention described below, rather than the "coil ends" (the portions that electrically connect the portions of the distributed wound windings inserted into the slots on both sides of the core) that constitute the coils themselves. In other words, simply twisting these "connecting portions" disclosed in JP 5 394 058 B2 does not allow for increasing the winding density at the coil ends to prevent the occurrence of copper loss, and thus cannot improve the efficiency of the electromechanical device at the coil ends.

[0019] Thus, typical problems with this type of coil that need to be solved comprehensively and simultaneously are the following: (A) Both round and rectangular wires should be able to be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires. (B) The manufacture and handling of the coils themselves should be easy. (C) Inserting the coils into the slots should be made easier. (D) The fill factor of the coils in the slots should be increased. (E) The coil heads should be reduced in size when used in an electromechanical device. (F) The uneven inductance in each winding to increase efficiency when used in an electromechanical device should be capable of being compensated. (G) As a result, the electromechanical device should be made compact and efficient, and the manufacture of the electromechanical device itself should also be simplified.

[0020] As suggested in the patent literature cited above, these problems are gradually being addressed. SUMMARY OF THE INVENTION Problems to be solved by the invention

[0021] In view of the foregoing, the inventors have considered how to obtain a coil that achieves the above-mentioned objects (A) to (G) in a comprehensive and simultaneous manner, and devised the following invention: “Coil 10 to be installed in a slot 22 between teeth 21 of a stator core or rotor 20, for an electromechanical device that converts electrical energy and mechanical energy, comprising: a first bearing portion 11a and a second bearing portion 11b to be supported in the slots 22, and a first coil end 12a and a second coil end 12b continuous between the first and second bearing portions 11a and 11b, formed by winding one or more windings 10A; and two holding means 30 that hold the windings 10A forming the first support portion 11a and the second support portion 11b while maintaining the alignment of the windings 10A one after another; wherein, when the two holding means 30 are rotated with respect to each other, a twisted portion 10d can be formed in the first coil head 12a and the second coil head 12b while maintaining the alignment of the first support portion 11a and the second support portion 11b in sequence, and the coil 10 can be mounted in the slot 22 between the teeth 21." However, the inventors then realized the need to explain the holding means 30, which is a prerequisite for the above-mentioned invention. This is because in a conventional distributed wound coil, the first shape the coil takes is as in Fig. 25 (b), that of the bobbin around which the coil was wound, a shape that is easily undone in subsequent steps in the process. Furthermore, if any force is applied to the distributed wound coil, which still has the shape of the bobbin, causing necessary bending or deformation, and the coil is finally inserted into the slot, the initial winding sequence or relative positions of the windings are easily destroyed, which must be prevented. The aforementioned holding means 30 meets this requirement. In other words, an object of the present invention is to provide a coil holding means that enables the formation of a twisted portion 10d in the first and second coil heads 12a and 12b while maintaining the alignment of the first and second support portions 11a and 11b of the coil 10 in sequence, thereby simplifying the manufacture of coils, allowing easy insertion of the coils into the slots with a high filling factor of the windings in the slots, thus enabling the coil heads of the coil to be downsized when used in an electromechanical device. Means to solve the problems

[0022] In order to solve the above-mentioned problems, the invention according to claim 1 employs the following means, which are described here using the reference numerals used in the following description of an embodiment of the present invention: “A pair of holding means 30 adapted to hold a coil 10 to be mounted in slots 22 between a plurality of teeth 21 of a core 20 for an electromechanical device that converts electrical and mechanical energy, each of the holding means 30 comprising: at least two base plates 32 which are openably coupled at one end; an outlet 31 formed between the other ends of the base plates 32, the outlet 31 being adapted to be aligned with an axial opening 23 of a slot 22; and a holding space 32a openable at the outlet 31, which, when the base plates 32 close, holds windings 10A forming a first support portion 11a and a second support portion 11b of the coil 10 while maintaining the alignment of the windings 10A. wherein one holding means 30 of the pair of holding means 30 holds the first bearing portion 11a of the spool 10 and the other holding means 30 of the pair of holding means 30 holds the second bearing portion 11b of the spool 10, and wherein, when the coil 10 is mounted in the slots 22, each holding space 32a communicates with an interior of the slot 22 through the axial opening via the holding means 30."

[0023] In other words, the holding means 30 are used throughout the entire process from the manufacture of the coils 10, which are to be mounted in slots 22 between several teeth 21 of a core 20 for an electromechanical device that converts electrical and mechanical energy, to the assembly or insertion of the coils 10 into the slots 22 between the teeth 21. During this process, the holding means 30 facilitate the manufacture of the coils 10 and the electromechanical device that utilizes the coils 10, facilitate the assembly or insertion of the coils 10 into the slots 22, and also increase the concentration of the windings in each slot 22, which ultimately leads to the manufacture of an armature 100, as shown in Fig. 1 or Fig. 22, with low non-uniform inductance.

[0024] As in the Fig. 2 (b), 3 (a) and 4 to 6, the holding means 30 according to claim 1 has a basic structure including at least two base plates 32 coupled at one end so as to be openable, an outlet 31 formed at the other end of the base plates 32, and a holding space 32a openable at the outlet 31.

[0025] As in the Fig. As shown in Figures 4 (a) to 4 (d), 5 and 6, the at least two base plates 32 have a generally rectangular shape and are coupled to the opposite side of the outlet 31 by means of hinges or the like so that they can be opened and closed. Accordingly, they can take two shapes, as shown by solid lines and imaginary lines in Figures Fig. 4 (a) to 4 (c) and 5, wherein one base plate 32 is closed (solid lines) or open (fictitious lines) with respect to the other. The reason why "at least" two base plates 32 are mentioned here is that, while two base plates 32 are required for one holding means 30, as in Fig. 4, are sufficient, the holding means 30 also as in Fig. 5, wherein two base plates 32 are provided on each side of a central base plate 32 for opening and closing, thereby forming two holding spaces 32a for the windings 10A.

[0026] If one base plate 32 is closed with respect to the other, at least one holding space 32a for windings 10A is formed between the base plates 32. If the base plates 32 are closed, the windings 10A are held in the holding space 32a, maintaining their alignment. If the base plates 32 are opened, the holding space 32a will be open, and at this time the holding means 30 has one of its base plates 32 inserted into an insertion groove 41 of a coil former 40, as shown in the Fig. 2 (b) or Fig. 8, so that the receiving of the first bearing portion 11a or second bearing portion 11b of the spool 10 is prepared.

[0027] Such holding means 30 are used in a manufacturing process for producing coils 10 and for inserting or mounting the coils 10 in the slots 22 of a core 20 according to an assembly method described later. Although the coils 10 are mounted on a core 20 of an armature, as shown, for example, in Fig. 1, it goes without saying that they can also be applied to a rotor of an electromechanical device. Furthermore, as long as the core 20 or rotor has a plurality of teeth 21 on which the coils 10 are mounted and slots 22 between the teeth 21, the core 20 or rotor can be either of the split or block type.

[0028] As in the Fig. 2 (a) and Fig. As shown in Figure 3 (a), each coil 10 has first and second support portions 11a and 11b to be supported in the slots 22 described later, and first and second coil ends 12a and 12b arranged continuously between the first and second support portions 11a and 11b and on the outside of the core 20, and the parts of the coil 10 constituting the first support portion 11a and the second support portion 11b are held by two holding means 30 as described above. In addition, in each coil 10, as shown in Fig. 2 (b), between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A constituting the coil 10, the radii of the loop winding portions formed by the windings 10A vary continuously or stepwise.

[0029] This coil 10 is easily, as in Fig. 2, by winding one or more windings 10A ( Fig. 2 shows a case where two windings 10A are wound simultaneously around a coil former 40. The coil 10 can thus be formed by winding the windings 10A around a coil former 40 that is cylindrical or frame-shaped, so that between a first radial section formed by a winding start section 10a and a second radial section formed by a winding end section 10b of the windings 10A forming the coil, the radii of the loop winding sections formed by the windings 10A change continuously or stepwise, as shown in Fig. 2 (b).

[0030] As described above, the coils 10 are formed by winding around a coil body 40 and can thus be manufactured without the need for a complicated manufacturing process or apparatus.

[0031] In the coil body 40, in order to continuously change the radii of the loop winding portions formed by the windings 10A, two insertion grooves 41 are formed along the axial direction of the coil body 40, as shown in Fig. 2 (b). Thus, by inserting one base plate 32 of a holding means 30 into each insertion groove 41 and closing the other base plate 32, the windings 10A wound around the bobbin 40 are held on the first and second support portions 11a and 11b, maintaining their alignment with each other.

[0032] As in the Fig. As shown in Figures 4 to 7, the holding means 30 used in an embodiment described later consists of two base plates 32 coupled on one side so that they can be opened and closed, and after inserting one of the base plates 32 into the insertion groove 41, the second base plate 32 is closed to hold the coils 10A. Accordingly, an outlet 31 is formed between these two base plates 32, through which the held coils 10A can be ejected.

[0033] These holding means 30 are then removed with respect to the coil former 40 while holding the first and second support portions 11a and 11b of the windings 10A to remove and separate the coil 10 from the coil former 40. In other words, moving the coil former 40 and the holding means 30 with respect to each other results in a coil 10, wherein the windings 10A forming the first and second support portions 11a and 11b are held parallel to each other by the holding means 30.

[0034] This embodiment employs a plurality of coil formers 40 integrated in the axial direction, with the large-diameter ends forming pairs and the small-diameter ends forming pairs. In this case, the windings 10A can be cut at locations other than between adjacent coils 10, so that a chain of two coils 10 or a chain of four coils 10 is formed, as shown in FIG. Fig. 26 (b), in which the coils 10 are electrically connected at the winding start portions 10a and winding end portions 10b.

[0035] Furthermore, in a case where the windings 10A are caused to change stepwise between the winding start portions 10a and the winding end portions 10b, a coil body 40 as shown in Fig. 8, which is continuously formed from a cylinder with an outer diameter that changes in three steps. Naturally, the surface of the cylinder that forms the steps is parallel to the axis of the coil body 40, so that the windings 10A wound around these cylinder surfaces cannot be displaced. The design of all other parts of this coil body 40, which changes in steps, is similar to that shown in Fig. 2 (b) shown coil body.

[0036] Immediately upon completion of the coil 10, the two holding means 30 hold the coil 10 at two points, as shown in Fig. 2 (a), so that the windings 10A constituting the coil 10 do not wind up. As mentioned above, the parts held by the holding means 30 are the first and second support portions 11a and 11b, and the parts projecting from the holding means 30 are the first and second coil ends 12a and 12b, which are electrically continuous between the first and second support portions 11a and 11b. A twisted portion 10d, as described below, is formed in the first and second coil ends 12a and 12b.

[0037] When the holding means 30 are rotated with respect to each other while holding the first and second bearing portions 11b, a twisted portion 10d, such as shown in the Fig. 9 to 11, is formed in the first and second coil ends 12a and 12b. In this twisted portion 10d, at the portion having the smallest radius than the winding start portion 10a, increasing the rotation angle of the holding means 30 will cause the windings to twist toward the twisted portion 10d in order from the winding start portion 10a, and a space is formed around the twisted portion 10d in which a twisted portion 10d of another coil 10 can be arranged.

[0038] When assembling the coil 10, the twisted section 10d of another coil 10 will fit into the twisted section 10d of the first coil 10 without spaces, so that, as shown in the Fig. 1 (a) and Fig. 22 (a), the windings 10A are arranged with a minimum length of the coil ends, which not only reduces the copper loss or iron loss in the coil ends, but also, as shown in the Fig. 1 (b) and Fig. 22 (b), a much smaller height of the coil heads is possible than in the case shown in Fig. 26 (a). The overall volume of a resulting electromechanical device (e.g., a motor) can therefore be reduced.

[0039] Furthermore, by applying a force to the center of the first coil head 12a and the second coil head 12b while they are held parallel to each other by the holding means 30, a curved portion 10c as shown in Fig. 23 (a). At this time, with the radii of the winding sections formed by the windings 10A continuously or gradually changing between the first radial section formed by the winding start section 10a and the second radial section formed by the winding end section 10b of the windings 10A, a next coil receiver 10e, as shown in Fig. 23 (c), are also formed on the outside of the first and second coil ends 12a and 12b. When mounting the coil 10, the next coil receiver 10e of another coil 10 is inserted into the next coil receiver 10e. This not only reduces the copper loss or iron loss in the coil ends, but, as shown in the Fig. 1 (b) and Fig. 22 (b), the height of the coil heads can also be adjusted with respect to the conventional Fig. 26 (a) example can be significantly reduced.

[0040] The coils 10 manufactured as described above are inserted into the slots 22 formed between the teeth 21 of the core 20. There are two exemplary types of insertion methods or assembly methods: the one-slot-one-coil type and the one-slot-two-coil type. These methods are described individually below. (One slot-one coil assembly method)

[0041] In this type of assembly method, a coil 10 is inserted into a slot 22 of the core 20 of an electromechanical device, as shown in Fig. 24, with the aim of producing an armature 100 as shown in Fig. 22. First, as shown in Fig. 23, a curved portion 10c (forming a next coil receiver 10e described later) is formed in both the first and second coil ends 12a and 12b located between two holding means 30 holding the coil 10.

[0042] As a result, as in Fig. 23 (a) to 23 (c), since the first radial portion formed by the winding start portion 10a and the second radial portion formed by the winding end portion 10b of the windings 10A change continuously or stepwise with respect to the holding means 30, a next coil receiver 10e, in which the winding end portion 10b is the widest opening, is naturally formed on the lower side of the curved portion 10c between both the first and second coil ends 12a and 12b and the holding means 30, as shown in Fig. 23 (c).

[0043] When the spool 10 in which this curved portion 10c is formed is inserted, the outlets 31 of the holding means 30 holding the first spool 10 are aligned with the axial openings 23 of the two respective slots 22, which are separated from each other by a specified distance. Next, the first and second bearing portions 11a and 11b, which are held by the respective holding means 30, are pressed into the slots 22 through the outlets 31.

[0044] The next coil 10 is then inserted into the next slot 22 after the slot 22 in which the first coil 10 is mounted, so that the curved portion 10c of the next coil 10 is inserted into the curved portion 10c of the first coil 10. Since the second coil 10 also has a curved portion 10c in this case, this curved portion 10c is stored without any spaces within the curved portion 10c of the first coil 10.

[0045] When subsequent coils 10 are mounted on a core 20 in the same way, the curved portions 10c of, for example, the first coil ends 12a protrude inwardly where the rotor of the core 20 is to be arranged, and the curved portions 10c are therefore bent toward the opposite side, as shown in the Fig. 23 (c) and Fig. 24. When the coils 10 are mounted on a rotor, the curved portions 10c of the first and second coil ends 12a and 12b do not need to be bent since they protrude toward the center.

[0046] The curved portions 10c in this one slot-one coil method correspond to the next coil receivers 10e of the one slot-two coil method described below. (One slot-two coil assembly method)

[0047] This type of assembly method differs from the one-slot-one-coil method described above. As in Fig. 20, the first bearing portion 11a of a first coil 10 and the second bearing portion 11b of a second coil 10 are inserted or mounted into each of the plurality of slots 22 of a rotor 20, with the aim of producing an armature 100 as shown in Fig. 1. In this assembly process, as shown in Fig. As shown in Figure 20 (a), the first and second support portions 11a and 11b of the first coils 10 are each supported in a first slot 22 and another slot 22 separated from the first slot 22 by a specified distance. At this time, the windings 10A constituting the first and second support portions 11a and 11b are in a wound state within the slots 22, leaving space for the insertion of the first and second support portions 11a and 11b of the following coils 10.

[0048] In this assembly method, the outlet 31 of the holding means 30, which holds the first bearing portion 11a of the coil 10, is aligned with the axial opening 23 of a slot 22, and the first bearing portion 11a is inserted into the slot 22. If the second bearing portion 11b of a subsequent coil 10 has not yet been inserted into the slot 22, the windings 10A constituting the first bearing portion 11a are stored in the slot 22 in a wound state, so that when the second bearing portion 11b of a subsequent coil 10 is forcibly inserted into the slot 22, the first bearing portion 11a of the first coil 10 and the second bearing portion 11b of the subsequent coil 10 are tightly packed together. The insertion is carried out by means of an ejection plate which pushes the windings 10A out of the holding means 30, but it can also be carried out automatically by means of the elastic force inherent in the windings 10A.

[0049] Next, by rotating the holding means 30 that holds the second bearing portion 11b of the spool 10 with respect to the holding means 30 that holds the first bearing portion 11a, a rotated portion 10d is formed as exemplified in Fig. 9, in the first coil head 12a and in the second coil head 12b. This twisted section 10d is formed by relative rotation of two holding means 30 in the Fig. 3 (a) shown state.

[0050] When this twisted portion 10d is formed, the radii of the loop winding portions formed by the windings 10A change gradually between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A. Therefore, in the twisted portion 10d, the winding portions are twisted in ascending order from the winding portion with the smallest radius to the winding portion with the largest radius, and a space is formed around the first coil end 12a and second coil end 12b of the first coil 10, in other words, a next coil receiver 10e in which a twisted portion 10d of a second coil 10 can be arranged in a closely connected state, as shown in Fig. 10 (b) shown.

[0051] Next, the outlet 31 of the holding means 30 holding the second bearing portion 11b of the spool 10 is aligned with the axial opening 23 of another slot 22 separated from the above-mentioned slot 22, and the second bearing portion 11b is pressed into this slot 22 by the ejection plate of the holding means 30.

[0052] The next coil 10 is then inserted into the other slot 22, which is separate from the slot 22 in which the previous coil 10 is mounted, while the twisted portion 10d and the next coil receiver 10e formed by the above-mentioned method are superimposed on the twisted portion 10d and the next coil receiver 10e of the previous coil 10. This process is then repeated.

[0053] At this time, the center of the twisted portion 10d of the previous coil 10 is more constricted than the peripheral portions due to twisting, so that the peripheral portions of the twisted portion 10d are in an expanded state. Therefore, a space is formed near the twisted portion 10d of the coil 10, in other words, a next coil receiver 10e. The twisted portion 10d of the next coil 10, which is to be inserted into the next slot 22 separated from the first slot 22 by the distance between the slots 22, is to be stored in this next coil receiver 10e in a tightly connected state.In other words, the twisted portion 10d of the next coil 10 is arranged to be intertwined with the twisted portion 10d of the previous coil 10, and when the insertion of the previous coil 10 and the adjacent next coil 10 is completed, the twisted portions 10d and next coil receiver 10e are in a closely connected state.

[0054] In the final step of the insertion process, where two distributed wound coils 10 are inserted into a plurality of slots 22 in the "one slot-two coils" configuration, there will naturally be cases where the previously inserted coils 10 become obstructions. The final step is understood to mean a step in which, when the first bearing portions 11a of the first to seventh coils 10 are inserted into the first to seventh slots 22 in this order, respectively, the second bearing portions 11b of the last n ten up to n-6 tenReel 10 in the last n ten up to n-6 ten Slot 22 can be inserted.

[0055] Thus, in the last step of the insertion process, with respect to a slot 22 into which the second bearing portion 11b is to be inserted, but a first bearing portion 11a of the previous spool 10 has already been inserted, the first bearing portion 11a is temporarily taken out, and the second bearing portion 11b of the next spool 10 is inserted and pressed into the outside of the slot 22, while the first bearing portion 11a is reinserted so that it is located on the inside.

[0056] A coil mounting device 50 as shown in Fig. 12, is used for inserting the coils 10 into the slots 22. This coil mounting device 50 has a coil rack 51 that can accommodate several coils 10 held in holding means 30, and a core rotating device 52 that rotates and positions the core 20 one after the other, and is designed to transport the coils 10 held in the holding means 30 from the coil rack 51 to the core 20, which is stored by the core rotating device 52. The coils 10 are arranged in the coil rack 51 in a Fig. 12 shown manner.

[0057] The coil mounting device 50 also includes a first auxiliary arm 53a and a second auxiliary arm 53b, which are individually rotated and moved into and out of the core 20 on the core rotating device 52 and are configured to operate depending on the state of the coils 10, for example, to rotate the second support portion 11b of each coil 10 to form the twisted portion 10d. At this time, the holding means 30 according to the present invention are used.

[0058] As described above, the coil 10 manufactured using the holding means 30 according to claim 1 consists of one or more windings 10A wound by distributed winding and is held at two portions by two holding means 30. From the completion of the coil 10 until it is stored in a special slot 22, these holding means 30 maintain the orientation of the distributed wound windings 10A, in other words, prevent them from being wound up, thereby allowing deformation of the first and second coil ends 12a and 12b of the coil 10 until storage without changing the shape of the first and second storage portions 11a and 11b.

[0059] The coil 10 is wound by distributed winding as proposed in Japanese Unexamined Patent Application Publication No. 2009-195005, in which coils are wound over a plurality of slots and coils that are in phase or out of phase with each other are overlapped at the coil ends, and has first and second support portions 11a and 11b supported in two respective slots 22. As shown in the Fig. 2 (a) and Fig. As shown in Figure 3 (a), between these first and second support portions 11a and 11b, the first and second coil ends 12a and 12b are exposed at the upper and lower sides of the drawing, respectively. Furthermore, as shown in Fig. 2 (a), both ends of the windings 10A are projected from the coil 10 as connecting leads 10C for electrically connecting the coil 10 to another coil 10 or a power source.

[0060] The coils 10 can be formed as a plurality of coils 10 that are electrically continuously connected to each other. In this case, as shown in Fig. 10, connecting wires 10C are provided, which protrude from one end surface side (a predetermined side) of the core 20. By these connecting wires 10C, the coils 10 are electrically continuously connected to each other. Further, in the coils 10 electrically connected via the connecting wires 10C, the connecting wires 10C of the coils 10 at each end are used as a power supply line and a ground wire, respectively. Of course, the windings 10A constituting the coils 10 besides the connecting wires 10C are used as a first support portion 11a and a second support portion 11b, and a first coil end 12a and a second coil end 12b, which will be described below, and the windings 10A constituting each of these parts are electrically continuously connected.

[0061] Such a coil 10 has a basic structure in which one or more windings 10A are wound around a cylinder or frame, forming the first and second support portions 11a and 11b, which are to be supported in the slots 22 defined by the teeth 21, and the first and second coil ends 12a and 12b, which are continuous between the first and second support portions 11a and 11b and are arranged on the outside of the core 20. The first support portion 11a and the second support portion 11b of the coil 10 are held by the two holding means 30 in a state in which the alignment of the windings 10A is maintained. Accordingly, this coil 10 enables the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires.

[0062] It is important that the portions of the coil 10 constituting the first and second support portions 11a and 11b are held by the support means 30 so that the alignment of the windings 10A is maintained. This is because, as will be stated later in the description of the method for mounting the coil 10 on the teeth 21, when a plurality of coils 10 are mounted on the teeth 21, in a case where a curved portion 10c is formed in the first and second coil heads 12a and 12b (i.e., when one coil is supported in a slot), or in a case where a twisted portion 10d is formed in the first and second coil heads 12a and 12b and the twisted portions 10d of each coil 10 overlap with each other (i.e.,When two coils are mounted in a slot, the first and second coil ends 12a and 12b of the first coil must naturally be deformed so that the first and second coil ends 12a and 12b of the next coil 10 can overlap without gaps. Accordingly, these coils 10 manufactured using the holding means 30 enable the following: (D) The fill factor of the coils in the slots can be increased.

[0063] In both the case where one coil is stored in a slot and the case where two coils are stored in a slot, the distributed wound coils 10 are stored after being wound in the slots shown in Fig. 9 (b). In other words, considering a spool 10, the position of the first support portion 11a supported in the first slot 22 is on the opposite side with respect to the second support portion 11b supported in the second slot 22 separated from the first slot by a certain distance due to the twisted portion 10d of the spool 10.

[0064] In this state, that is, when the first support portion 11a and the second support portion 11b are located on opposite sides due to the twisted portion 10d of the coil 10, when the first portion of the windings 10A of the first support portion 11a, which is supported in the first slot 22, is located on the inside, as shown in Fig. 20 (a), the last portion of the windings 10A of the second support portion 11b, which is supported in the second slot 22 separated from the first slot by a certain distance, will be located on the outside of the second slot 22.

[0065] Generally, when a distributed-wound coil without a twisted section is supported in two slots, the first section of the windings of the first support section, supported in a first slot, and the last section of the windings of the second support section, supported in a second slot separated from the first slot by a certain distance, will be in the same position in each slot. Since the slots, both on the rotor side and the core side, are formed radially with respect to the center of the armature, the dimensions of their inner sides and the dimensions of their outer sides are different. Thus, when a distributed-wound coil without a twisted section is supported in two slots, the windings are supported in the same position, causing uneven inductance in the inner and outer windings (wires), resulting in an overall decrease in the coil's efficiency.The reason for this is that if an identical voltage is applied to the wires at the same time, a larger current will flow in the wires at lower inductance and this uneven inductance will work towards reducing the overall efficiency of the coil.

[0066] In the coil 10, the presence of the twisted portion 10d formed by the holding means 30 according to the present invention means that, as exemplified in Fig. 10 (b) or Fig. 20 (a), when the first portion of the windings 10A of the first support portion 11a supported in a first slot 22 is located on the inside, the last portion of the windings 10A of the second support portion 11b supported in the second slot 22 separated from the first slot by a certain distance will be located on the outside of the second slot 22, thereby reducing or eliminating the uneven inductance in the parts (wires) of the coil 10, so that more magnetic flux is generated.

[0067] By reducing or eliminating the uneven inductance in the parts (wires) of the coil 10, the overall decrease in the efficiency of the coils 10 is prevented. As a result, the efficiency of an electromechanical device using these coils 10 can be improved, and the electromechanical device itself will have high output power and can be made smaller and lighter.

[0068] As described above, the presence of the twisted portion 10d formed by the holding means 30 according to the present invention in the coils 10 reduces or eliminates uneven inductance in the parts (wires), resulting in an electromechanical device in which the coil 10 usually has a high output and can be made smaller and lighter. As a result, the coil 10 enables the following: (F) Uneven inductance in each winding can be compensated to increase coil efficiency when used in an electromechanical device.

[0069] The use of the coil 10 formed by the holding means 30 according to claim 1 allows the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires. (B) The manufacture and handling of the coils is easy. (C) Inserting the coils into the slots can be done easily. (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device. (F) The uneven inductance in each winding can be compensated to increase coil efficiency when used in an electromechanical device. (G) As a result, the armature can be made compact and efficient, and the electromechanical device can be easily manufactured.

[0070] Accordingly, the holding means 30 according to claim 1 can form a twisted portion 10d in the first and second coil heads 12a and 12b while maintaining the alignment of the windings forming the first and second support portions 11a and 11b of the coil 10, which enables easy manufacture and handling of the coils, easy insertion into the slots, and a high filling factor of the windings in the slots, resulting in smaller coil heads when used in an electromechanical device.

[0071] In order to solve the above-mentioned problems, the invention according to claim 2 employs the following means with respect to the holding means 30 for an electromechanical device according to claim 1: "A stopper 31a is provided on at least one of the base plates 32 near the outlet 31 so that the coils 10A in the holding space 32a do not jump out. In order to solve the above-mentioned problems, the invention according to claim 2 sets the following means with respect to the coil 10 for an electromechanical device according to one of claims 1 or 2: “The outlet 31 of each retaining means 30 is provided with lips 36 which guide the coil 10 into the axial opening 23 of the slot 22.”

[0072] The two holding means according to claim 1, as described above, hold a distributed wound coil 10 at two locations. From the completion of the coil 10 until it is stored in a specific slot of the core 20, these holding means 30 prevent the distributed wound windings 10A from unraveling and allow the deformation of the first and second coil ends 12a and 12b of the coil 10 before storage without causing deformation of the first and second storage sections 11a and 11b. The holding means 30 also maintains the alignment of the windings 10A constituting the first and second storage sections 11a and 11b.

[0073] The holding means 30 according to claim 1, as described above, inserts the windings 10A, which form the first and second support portions 11a and 11b of the coil, between the base plates 32, and the friction thereof is sufficient to maintain the alignment of the windings 10A. However, this may not be sufficient if another force counteracting this friction is applied from elsewhere. Therefore, the holding means 30 according to claim 2 comprises a stopper 31a provided near the outlet 31 of at least one of the base plates 32 to prevent the windings 10A from popping out of the holding space 32a.

[0074] As in the Fig. As shown in Figures 4(b) to 4(d), there are various shapes of the stopper 31a. However, to prevent the coils 10A from jumping out of the holding space 32a, the most suitable arrangement is to provide the stopper 31a near the outlet 31 of the holding means 30. This is because the outlet 31 is formed at the end of the reciprocally opening and closing base plates 32, from which the coils 10A are inserted.

[0075] In the Fig. 4 (b), a fixed stop 31a is formed at the end of the base plate 32 opposite the base plate 32 which is inserted into the insertion groove 41 of the above-mentioned coil body 40. In the example shown in Fig. 4 (c), a stop 31a is formed so that opening and closing is possible at the end of the base plate 32 opposite the base plate 32 which is inserted into the insertion groove 41 of the coil body 40. Finally, in the example shown in Fig. 4 (d), an insertion opening is formed near the outlet 31 of the mutually opening and closing base plates 32, and the stopper 31a (in the form of a pin) is adapted to be inserted into this insertion opening so as to function as a stopper.

[0076] In all the Fig. In the cases shown in Figures 4(b) to 4(d), the stopper 31a prevents the coils 10A from popping out of the holding space 32a, even if a force that would cause the coils 10A to pop out of the holding space 32a is applied from elsewhere. Thus, all of these examples maintain the alignment of the coils 10A.

[0077] Accordingly, the holding means 30 according to claim 2 comprise stops 31a which prevent the windings 10A in the holding space 32a from jumping out during operation and ensure the formation of a twisted portion 10d in the first and second coil heads 12a and 12b, while maintaining the alignment of the windings forming the first and second bearing portions 11a and 11b of the coil 10, thereby simplifying the manufacture of the coils, allowing easy insertion of the coils into the slots with a high filling factor of the windings in the slots, and consequently allowing the downsizing of the coil heads of the coil when used in an electromechanical device. Effects of the invention

[0078] As described above, the present invention has the following structural features: “A pair of holding means 30 adapted to hold a coil 10 to be mounted in slots 22 between a plurality of teeth 21 of a core 20 for an electromechanical device that converts electrical and mechanical energy, each of the holding means 30 comprising: at least two base plates 32 which are openably coupled at one end; an outlet 31 formed between the other ends of the base plates 32, the outlet 31 being adapted to be aligned with an axial opening 23 of a slot 22; and a holding space 32a openable at the outlet 31, which, when the base plates 32 close, holds windings 10A forming a first support portion 11a and a second support portion 11b of the coil 10 while maintaining the alignment of the windings 10A. wherein one holding means 30 of the pair of holding means 30 holds the first bearing portion 11a of the spool 10 and the other holding means 30 of the pair of holding means 30 holds the second bearing portion 11b of the spool 10, and wherein, when the coil 10 is mounted in the slots 22, each holding space 32a communicates with an interior of the slot 22 through the axial opening via the holding means 30." Due to these features, the present invention provides a holding means 30 that allows the formation of a twisted portion 10d in the first and second coil ends 12a and 12b while maintaining the alignment of the windings forming the first and second support portions 11a and 11b of the coil 10, thereby simplifying the manufacture of coils, allowing the coils to be easily inserted into the slots with a high filling factor of the windings in the slots, and consequently reducing the size of the coil ends when used in an electromechanical device. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Fig. 1 shows a core for constructing an armature 100 according to an embodiment of the present invention, in which two coils 10 are mounted in a slot, where (a) is a plan view and (b) is a front view; Fig. Fig. 2 shows a coil 10 manufactured using the holding means 30 according to an embodiment of the invention, where (a) is a perspective view and (b) is a cross-sectional view illustrating the manufacturing process; Fig. Figure 3 shows the coil 10, where (a) is a front view of two holding means 30 holding the windings 10A placed in a plane, and (b) is a representative plan view of seven windings 10A; Fig. Figure 4 is a cross-sectional view of the retaining means 30, which is a side view taken along line 2-2 in Fig. 3 (a) shows, where (a) is a side view of an example without a stopper 31a, (b) is a side view of an example with a stopper 31a provided near the outlet 31, (c) is a side view of an example with a stopper provided so as to allow opening and closing near the outlet 31, and (d) is a side view of an example with a stopper 31a in the form of a pin to be inserted into an insertion opening provided near the outlet 31; Fig. Fig. 5 is a side view of a holding means 30 where two base plates 32 for opening and closing are provided on both sides of the center of the base plate 32; Fig. Figure 6 is a partially enlarged plan view where the outlet 31 of the holding means 30 is provided with lips 36 which guide the windings into the slot 22; Fig. Fig. 7 shows a holding means 30 having a pivot plate 33 provided with a stopper 31a, where (a) is a side view of a state where the outlet 31 is closed by the stopper 31a, and (b) is a side view of a state where the pivot plate 33 is rotated in an opening direction of the stopper 31a to open the outlet 31; Fig. 8 is a cross-sectional view of a coil former 40 used to form a coil 10 having a radius that changes in steps; Fig. 10 is a side view of two coils 10 held by the holding means 30, where the coils 10 are electrically connected by a connecting wire 10C; Fig. Fig. 11 is a plan view of a loop winding of a twisted portion 10d and a next coil receiver 10e formed in each of the Fig. 10 shown two coils 10; Fig. 12 is a general perspective view of a coil mounting device 50 for mounting the coils 10 in the slots 22; Fig. Fig. 13 shows a coil 10 held by the holding means 30, where (a) is a front view of two holding means 30 holding the windings 10A arranged parallel to each other, and (b) is a representative plan view of six windings 10A; shows a first of seven steps of a method in which a coil 10 is inserted into two slots 22 with a coil mounting device 50, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 14 shows a second step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 15 shows a third step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 16 shows a fourth step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 17 shows a fifth step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 18 shows a sixth step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 19 shows a seventh and final step, where (a) is a partial plan view of the core 20 and (b) is an enlarged plan view of the coil 10 and the holding means 30 at that time; Fig. Fig. 20 illustrates the positional relationship when two coils 10 are stored in the slots 22, where (a) is a partial plan view of the core 20 when the first coil 10 is inserted, and (b) is a partial plan view of the core 20 when the second coil 10 is inserted; Fig. Fig. 21 is a partial plan view of the core 20, showing how seven coils 10 are simultaneously stored in sequence in the slots 22; Fig. Fig. 22 shows a core with a coil 10 mounted in a slot, where (a) is a plan view and (b) is a front view; Fig. 23 shows a coil 10 for constructing the armature 100 according to the embodiment of the present invention, the coil 10 having curved portions 10c and next coil receivers 10e, where (a) is an enlarged plan view of two parallel-arranged holding means 30, (b) is a front view thereof, and (c) is a cross-sectional view taken along line 1-1 in (a); Fig. Fig. 24 is a partial plan view of the core 20, illustrating the positional relationship when a coil 10 is stored in a slot 22; Fig. Fig. 25 shows the prior art proposed in Japanese Unexamined Patent Application Publication No. JP H11-312621 A, where (a) is a plan view of a stator and (b) is a perspective view of a coil; Fig. Fig. 26 shows the prior art proposed in Japanese Unexamined Patent Application Publication No. JP 2009 - 195 005 A, where (a) is a perspective view of a stator and (b) is a perspective view of a coil; and Fig. 27 is a perspective view of a coil insertion device proposed in Japanese Patent No. JP 5 394 058 B2. DESCRIPTION OF THE EMBODIMENTS

[0079] The invention as defined in the claims above will now be described with reference to the embodiments illustrated in the drawings. Fig. 2 (b), 3 (a) and 4 to 6 show a holding means 30 according to claim 1, wherein this holding means 30 comprises at least two base plates 32 coupled at one end so as to be openable, an outlet 31 formed at the other end of the base plates 32, and a holding space 32a openable at the outlet 31.

[0080] As in the Fig. As shown in Figures 4 (a) to 4 (d), 5 and 6, the at least two base plates 32 have a generally rectangular shape and are coupled to the opposite side of the outlet 31 by means of hinges or the like so that they can be opened and closed. Accordingly, they can take two shapes, as shown by solid lines and imaginary lines in Figures Fig. 4 (a) to 4 (c) and 5, wherein one base plate 32 is closed (solid lines) or open (fictitious lines) with respect to the other. The reason why "at least" two base plates 32 are mentioned here is that, while two base plates 32 are required for one holding means 30, as in Fig. 4, are sufficient, the holding means 30 also as in Fig. 5, wherein two base plates 32 are provided on each side of a central base plate 32 for opening and closing, thereby forming two holding spaces 32a for the windings 10A.

[0081] If one base plate 32 is closed with respect to the other, at least one holding space 32a for windings 10A is formed between the base plates 32. If the base plates 32 are closed, the windings 10A are held in the holding space 32a, maintaining their alignment. If the base plates 32 are opened, the holding space 32a will be open, and at this time the holding means 30 has one of its base plates 32 inserted into an insertion groove 41 of a coil former 40, as shown in the Fig. 2 (b) or Fig. 8, so that the receiving of the first bearing portion 11a or second bearing portion 11b of the spool 10 is prepared.

[0082] Fig. 6 shows a partially enlarged plan view in which the outlet 31 of the holding means 30 according to an embodiment of this invention is provided with lips 36 that guide the windings into the entrance of the slot 22. The lips 36 protrude (in this embodiment by about 0.5 mm to 1.0 mm) from the edges of the base plates 32 near one side (the side in the same direction as the axial direction of the joint that openably couples the base plates 32 to each other) of the base plate 32 near the outlet 31, as shown in Fig. 6. In addition, the space between the lips 36 is adjusted to the width of the axial opening 23 of the slot 22, so that the lips 36 of the closed base plates 32 enter the axial opening 23 of the respective slot 22, thereby guiding the windings 10A, which were located in the holding space 32a of the holding means 30, so that the windings 10A can enter the slot 22 with low friction.

[0083] Fig. Figure 1 shows a top view and a front view of a stator 100 employing coils 10 formed using the holding means 30 according to an embodiment of this invention, which is formed by inserting two distributed wound coils 10 into a slot 22. Furthermore, Fig. 22 shows a top view and a front view of a stator 100 using the same coils 10, which is formed by inserting a distributed wound coil 10 into a slot 22. These stators 100 constitute electromechanical devices that convert electrical energy and mechanical energy, such as a motor or a generator, and have a rotor (not shown) supported at their center.

[0084] Although the coils 10 formed using the holding means 30 according to an embodiment of the invention are mounted on, for example, the core 20 of the Fig. 1, it is understood that they can also be applied to the rotor of an electromechanical device. Furthermore, as long as the core 20 or rotor has a plurality of teeth 21 on which the coils 10 are mounted, and slots 22 between the teeth 21, the core 20 or rotor can be either of the split type, as shown in Fig. 25, or block type as shown in Fig. 26 shown.

[0085] Each coil 10 has, as shown in the Fig. 2 and Fig. 3 (a), first and second support portions 11a and 11b to be supported in the later-described slots 22, and first and second coil ends 12a and 12b that are continuous between the first and second support portions 11a and 11b and are to be arranged on the outside of the core 20, wherein the portions of the coil 10 that form the first support portion 11a and the second support portion 11b are held by two later-described robot hands or holding means 30. In addition, as shown in Fig. 2 (b), between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A forming the coil 10, the radii of the loop winding portions formed by the windings 10A are continuous.

[0086] The coil 10 is easily, as in Fig. 2 (b), by winding one or more windings 10A around a coil body 40 ( Fig. 2 shows two 10A windings wound simultaneously. Specifically, as in Fig. 2 (b), the coil 10 is formed by winding the windings 10A around a cylindrical or frame-shaped coil body 40, so that between a first radial section formed by a winding start section 10a and a second radial section formed by a winding end section 10b of the windings 10A, the radii of the loop winding sections formed by the windings 10A change continuously or stepwise.

[0087] As described above, the coils 10 are formed by winding around a coil former 40 as shown in Fig. 2 (b) or Fig. 8, and can thus be manufactured without the need for a complicated manufacturing process or device. Moreover, the windings 10A forming the coils 10 are not limited to rectangular wires as shown in Fig. 25 (b) and Fig. 26 (b), but they can also be commonly used round wires.

[0088] As in Fig. As shown in Fig. 2 (b), two insertion grooves 41 are formed in the axial direction of the coil bobbins 40, causing the radii of the loop winding portions formed by the windings 10A to continuously change. Therefore, by inserting the holding means 30 into these insertion grooves, the windings 10A wound around this coil bobbin 40 are held with the portions forming the first and second support portions 11a and 11b parallel to each other.

[0089] Each holding means 30 used in this embodiment consists of two rectangular plates coupled at one side so that they can be opened and closed. After inserting one of the plates into the insertion groove 41, the second plate is closed onto the windings 10A so that the windings 10A are held. Accordingly, an outlet 31 is formed between these two plates, as shown in FIGS. Fig. 3 (b) and Fig. 4 (b), and the held coils 10A can be ejected through this outlet 31. Robot hands can be used as these holding means 30.

[0090] If these holding means 30 are then removed with respect to the coil body 40 while holding the first and second support portions 11a and 11b of the windings 10A, the coil 10 is removed and separated from the coil body 40. In other words, by moving the holding means 30 and the coil body 40 with respect to each other, the windings 10A, which form the first and second support portions 11a and 11b of the coil 10, are held parallel to each other by the holding means 30.

[0091] The manufacturing method according to this embodiment employs a plurality of coil formers 40 integrated in the axial direction, with the large-diameter ends forming pairs and the small-diameter ends forming pairs. In this case, the windings 10A can be cut at locations other than between adjacent coils 10, so that a chain of two coils 10 or a chain of four coils 10 is formed, as shown in FIG. Fig. 26 (b), in which the coils 10 are electrically connected at the winding start portions 10a and winding end portions 10b.

[0092] The holding means 30 hold two sections of the newly completed coil 10, as in Fig. 2 (a) so that the windings 10A constituting the coil 10 do not wind up. As described above, the portions held by the holding means 30 are referred to as the first support portion 11a and the second support portion 11b. The portions projecting from the holding means 30 are the first coil end 12a and the second coil end 12b, which are electrically continuous between the first and second support portions 11a and 11b. As described below, in a case where a one-slot-one-coil assembling method is employed, a twisted portion 10d and associated next coil receiver 10e are formed in the first and second coil end 12a and 12b. When a one-slot-two-coil assembling method is employed, a twisted portion 10d is formed in the first and second coil end 12a and 12b.

[0093] In any case, in the first coil end 12a and the second coil end 12b of the finished coil 10, the radii of the loop winding sections formed by the windings 10A vary continuously or stepwise between a first radial section (which is smaller) formed by the winding start section 10a and a second radial section (which is larger) formed by the winding end section 10b of the windings 10A, as shown in the Fig. 2 (a) and Fig. 3 (a) shown.

[0094] Therefore, when the holding means 30 are relatively rotated while holding the first and second support portions 11a and 11b, a twisted portion 10d is formed in the first and second coil heads 12a and 12b, as exemplified in Fig. 9. In this twisted portion 10d, as the rotation angle of the holding means 30 increases, assuming that the winding start portion 10a has the smallest radius, the windings are twisted to the twisted portion 10d starting from the winding start portion 10a, thereby forming a space around the twisted portion 10d in which a twisted portion 10d of another coil 10 can be arranged.

[0095] Then, during assembly of the coil 10, the twisted section 10d of another coil 10 will fit seamlessly to the twisted section 10d of the first coil 10, so that the windings 10A are arranged with the shortest possible coil ends, as shown in the Fig. 1 (a) and Fig. 22 (a). This not only reduces the copper loss or iron loss in the coil ends, but, as shown in the Fig. 1 (b) and Fig. 22 (b), also the height of the coil heads can be adjusted with respect to the Fig. 26 (a), whereby the overall volume of an electromechanical device (e.g., a motor) can be reduced.

[0096] Furthermore, by applying a force to the center of the first coil head 12a and the second coil head 12b while they are held parallel to each other by the holding means 30, a curved portion 10c as shown in Fig. 23 (a). At this time, with the radii of the winding sections formed by the windings 10A continuously or gradually changing between the first radial section formed by the winding start section 10a and the second radial section formed by the winding end section 10b of the windings 10A, a next coil receiver 10e, as shown in Fig. 23 (c), are also formed on the outside of the first and second coil ends 12a and 12b. When mounting the coil 10, the next coil receiver 10e of another coil 10 is inserted into the next coil receiver 10e. This not only reduces the copper loss or iron loss in the coil ends, but, as shown in the Fig. 1 (b) and Fig. 22 (b), the height of the coil heads can also be adjusted with respect to the Fig. 26 (a) example can be significantly reduced.

[0097] The coils 10 manufactured as described above are inserted into the slots 22 formed between the teeth 21 of the core 20. There are two exemplary types of insertion methods or assembly methods: the one-slot-one-coil type and the one-slot-two-coil type. These methods are described individually below. (One slot-one coil assembly method)

[0098] In this type of assembly method, a coil 10 is inserted into a slot 22 of the core 20 of an electromechanical device, as shown in Fig. 24, with the aim of producing a stand 100 as shown in Fig. 22. First, as shown in Fig. 23, a curved portion 10c (forming the next coil receiver 10e) is formed in both the first and second coil heads 12a and 12b located between two holding means 30 holding the coil 10.

[0099] As a result, as in Fig. 23 (a) to (c), since the first radial portion formed by the winding start portion 10a and the second radial portion formed by the winding end portion 10b of the windings 10A change continuously or stepwise with respect to the holding means 30, a next coil receiver 10e, in which the winding end portion 10b is the widest opening, is naturally formed on the lower side of the curved portion 10c between both the first and second coil ends 12a and 12b and the holding means 30, as shown in Fig. 23 (c).

[0100] When the spool 10 in which this next spool receiver 10e is formed is inserted, the outlets 31 of the holding means 30 holding the first spool 10 are aligned with the axial openings 23 of the two respective slots 22, which are separated from each other by a specified distance. Next, the first and second bearing portions 11a and 11b, which are held by the respective holding means 30, are pressed into the slots 22 through the outlets 31.

[0101] The next coil 10, in which a next coil receiver 10e is formed with the above steps (a) to (c), is then inserted into the next slot 22 after the slot 22 in which the first coil 10 is mounted, so that the next coil receiver 10e of the next coil 10 is inserted into the next coil receiver 10e of the first coil 10. Since the second coil 10 in this case also has a next coil receiver 10e, as in Fig. 23, this next coil receiver 10e is stored without spaces within the next coil receiver 10e of the first coil 10.

[0102] If subsequent coils 10 are mounted on a core 20 in the same way, the next coil receivers 10e of, for example, the first coil heads 12a protrude inwards where the rotor of the core 20 is to be arranged, and the next coil receivers 10e are therefore bent towards the opposite side, as shown in the Fig. 23 (c) and Fig. 24. If the coils 10 are mounted on a rotor, the next coil receivers 10e of the first and second coil heads 12a and 12b do not need to be bent, since they protrude toward the center. (One slot-two coil assembly method)

[0103] This type of assembly method differs from the one-slot-one-coil method described above. As in Fig. 20, the first bearing portion 11a of a first coil 10 and the second bearing portion 11b of a second coil 10 are inserted or mounted into each of the plurality of slots 22 of a rotor 20, with the aim of producing a stator 100 as shown in Fig. 1. In this assembly process, as shown in Fig. As shown in Figure 20 (a), the first and second support portions 11a and 11b of the first coils 10 are each supported in a first slot 22 and another slot 22 separated from the first slot 22 by a specified distance. At this time, the windings 10A constituting the first and second support portions 11a and 11b are in a wound state within the slots 22, leaving space for the insertion of the first and second support portions 11a and 11b of the following coils 10.

[0104] In this assembly method, the outlet 31 of the holding means 30, which holds the first bearing portion 11a of the coil 10, is aligned with the axial opening 23 of a slot 22, and the first bearing portion 11a is inserted into the slot 22. If the second bearing portion 11b of a subsequent coil 10 has not yet been inserted into the slot 22, the windings 10A constituting the first bearing portion 11a are stored in the slot 22 in a wound state, so that when the second bearing portion 11b of a subsequent coil 10 is forcibly inserted into the slot 22, the first bearing portion 11a of the first coil 10 and the second bearing portion 11b of the subsequent coil 10 are tightly packed together. The insertion is carried out by means of an ejection plate which pushes the windings 10A out of the holding means 30, but it can also be carried out automatically by means of the elastic force inherent in the windings 10A.

[0105] Next, by rotating the holding means 30 that holds the second bearing portion 11b of the spool 10 with respect to the holding means 30 that holds the first bearing portion 11a, a rotated portion 10d is formed as exemplified in Fig. 9, in the first coil head 12a and in the second coil head 12b. This twisted section 10d is formed by relative rotation of two holding means 30 in the Fig. 2 (a) by 180 degrees (to the state shown in Fig. 9 (b) shown state).

[0106] When this twisted portion 10d is formed, the radii of the loop winding portions formed by the windings 10A change gradually between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A. Therefore, in the twisted portion 10d, the winding portions are twisted in ascending order from the winding portion with the smallest radius to the winding portion with the largest radius, and a space is formed around the first coil end 12a and second coil end 12b of the first coil 10, in other words, a next coil receiver 10e in which a twisted portion 10d of a second coil 10 can be arranged in a closely connected state, as shown in FIGS. Fig. 9 (b) and Fig. 20 (b) shown.

[0107] Next, the outlet 31 of the holding means 30 holding the second bearing portion 11b of the spool 10 is aligned with the axial opening 23 of another slot 22 separated from the above-mentioned slot 22, and the second bearing portion 11b is pressed into this slot 22 by the ejection plate of the holding means 30.

[0108] The next coil 10 is then inserted into the other slot 22, which is separate from the slot 22 in which the previous coil 10 is mounted, while the twisted portion 10d and the next coil receiver 10e formed by the above-mentioned method are superimposed on the twisted portion 10d and the next coil receiver 10e of the previous coil 10. This process is then repeated.

[0109] At this time, the center of the twisted portion 10d of the previous coil 10 is more constricted than the peripheral portions due to twisting, so that the peripheral portions of the twisted portion 10d are in an expanded state. Therefore, a space is formed near the twisted portion 10d of the coil 10, in other words, a next coil receiver 10e. The twisted portion 10d of the next coil 10, which is to be inserted into the next slot 22 separated from the first slot 22 by the distance between the slots 22, is to be stored in this next coil receiver 10e in a tightly connected state.In other words, the twisted portion 10d of the next coil 10 is arranged to be intertwined with the twisted portion 10d of the previous coil 10, and when the insertion of the previous coil 10 and the adjacent next coil 10 is completed, the twisted portions 10d and next coil receiver 10e are in a closely connected state.

[0110] In the final step of the insertion process, where two distributed wound coils 10 are inserted into a plurality of slots 22 in the "one slot-two coils" configuration, there will naturally be cases where the previously inserted coils 10 become obstructions. The final step is understood to mean a step in which, when the first bearing portions 11a of the first to seventh coils 10 are inserted into the first to seventh slots 22 in this order, respectively, the second bearing portions 11b of the last n ten up to n-6 tenReel 10 in the last n ten up to n-6 ten Slot 22 can be inserted.

[0111] Thus, in the last step of the insertion process, with respect to a slot 22 into which the second bearing portion 11b is to be inserted, but a first bearing portion 11a of the previous spool 10 has already been inserted, the first bearing portion 11a is temporarily taken out, and the second bearing portion 11b of the next spool 10 is inserted and pressed into the outside of the slot 22, while the first bearing portion 11a is reinserted so that it is located on the inside.

[0112] A coil mounting device 50 as shown in Fig. 12, is used for inserting the coils 10 into the slots 22. This coil mounting device 50 has a coil rack 51 that can accommodate several coils 10 held in holding means 30, and a core rotating device 52 that rotates and positions the core 20 one after the other, and is designed to transport the coils 10 held in the holding means 30 from the coil rack 51 to the core 20, which is stored by the core rotating device 52. The coils 10 are arranged in the coil rack 51 in a Fig. 3 shown manner.

[0113] The coil mounting device 50 further includes a first auxiliary arm 53a and a second auxiliary arm 53b which are individually rotated and moved into and out of the core 20 on the core rotating device 52 and are configured to operate depending on the state of the coils 10, for example, to rotate the second support portion 11b of each coil 10 to form the twisted portion 10d.

[0114] The insertion of the coils 10 into the core 20 using the coil mounting device 50 will now be described with reference to the Fig. 13 to 21 described.

[0115] This embodiment shows an example of a one-slot-two-coil insertion process in which a first support portion 11a of one coil 10 and a second support portion 11b of another coil 10 are supported in each of 48 slots 22 of a core 20. As exemplified in Fig. As shown in Fig. 13(a), the first support portion 11a of the first coil 10 is supported in the first slot 22, and the second support portion 11b of the coil 10 is supported in the 43rd slot 22 in a clockwise direction. In other words, a distributed winding process is performed in which the first and second support portions 11a and 11b of one coil 10 are supported in two slots 22 across five other slots 22.

[0116] First, a required number of coils 10 are placed on the coil rack 51 of the coil mounting device 50, shown in Fig. 12. The coils 10 are located in the Fig. 13 (b) by rotating one of the holding means 30 relative to the other so that the first and second storage sections 11a and 11b are aligned in a straight line. The required number of spools 10 is fixed in the spool rack 51 by storing two holding means 30, each holding a spool 10 in this state, in each gap of the spool rack 51.

[0117] Next, as in Fig. 13 (a), the coil mounting device 50 is operated with respect to the core 20 having the first to 48th slots 22, so that the holding means 30 holding the first support portion 11a of the first coil 10 faces the first slot 22. At this time, as shown in Fig. 13 (a), the tip of the first auxiliary arm 53a is moved into the core 20 so that a first guide channel 54a formed at the tip of the first auxiliary arm 53a faces the first slot 22 and the second support portion 11b of the coil 10 is outside the guide channel 54a (on the top of Fig. 13) is available.

[0118] In the Fig. 13, the two holding means 30, which were stored horizontally in the coil rack 51, are rotated 90 degrees to a vertical position. In other words, the two holding means 30 aligned in a vertical line are orthogonal to the axial opening 23 of the slot 22. In the state shown in Fig. 13, especially in Fig. In the state shown in Fig. 13 (a), the tip of the second auxiliary arm 53b is arranged with a second guide channel 54b on the right side of the first auxiliary arm 53a, so that the second guide channel 54b faces the 43rd slot 22 and is ready for supporting the second support portion 11b of the first spool 10.

[0119] If one looks at the state of the first coil 10, as in Fig. More specifically, as shown in Figure 13(b), the first support portion 11a is sandwiched between a base plate 32 and a pivot plate 33 at the bottom of the drawing. The lower end of the first support portion 11a is held by the tip of the closed pivot plate 33, so that the first support portion 11a cannot exit through the outlet 31. Furthermore, the holding means 30 that holds the second support portion 11b of the spool 10 at the top of the drawing has its outlet 31 at the upper end, and this outlet 31 is also closed by a closed pivot plate 33. The portions other than the first and second support portions 11a and 11b held by the holding means 30 are the first and second spool heads 12a and 12b, in which a twisted portion 10d has already been formed by relative rotation of the holding means 30.

[0120] Next, the coil mounting device 50 is operated so that, as shown in Fig. 14 (a), the holding means 30 holding the first bearing portion 11a is inserted into the first guide channel 54a of the first auxiliary arm 53a. Since this first guide channel 54a is a long, straight groove, the pivot plate 33 is pressed against the biasing force of the first engagement pin 34, so that the pivot plate 33 becomes parallel to the base plate 32, which opens the outlet 31 of the lower holding means 30, as shown in Fig. 14 (b).

[0121] Once the entire lower support member 30 is supported in the first guide channel 54a, a first stopper 55a provided on the first auxiliary arm 53a closes the upper portion of the first guide channel 54a, so that the first support portion 11a of the spool 10 will not accidentally pop out of the first guide channel 54a. At this time, the upper support member 30, which supports the second support portion 11b, is brought closer to the end of the first auxiliary arm 53a.

[0122] Now, as the lower holding means 30 is rotated clockwise, the first bearing portion 11a, which was held inside the lower holding means 30, starts to enter the first slot 22, and the outlet 31 of the upper holding means 30 is rotated to face the second guide channel 54b, as shown in the Fig. 15 to 17. The first bearing portion 11a of the spool 10 begins to enter the first slot 22 due to the force from the second bearing portion 11b, which is connected via the first and second spool heads 12a and 12b, as the upper holding means 30 is rotated clockwise. Of course, the first bearing portion 11a can be pressed into the slot 22 by other means.

[0123] As in Fig. As shown in Fig. 17, when the holding means 30 holding the second bearing portion 11b is brought to the opening of the second guide channel 54b with the coil mounting device 50, it is further pushed into the second guide channel 54b while being guided by the second engagement pin 35. At this time, the first bearing portion 11a is almost completely located in the outside of the respective slot 22. When the second bearing portion 11b is pushed into the slot 22 as shown in Fig. As shown in Figure 14, the closed state of the pivot plate 33 of the holding means 30 is released, causing the outlet 31 to open, allowing the second bearing portion 11b to enter the 43rd slot 22. A second stop 55b then closes the opening of the second guide channel 54b.

[0124] If the insertion of the second bearing section 11b is carried out up to the last step, the second bearing section 11b will fully enter the slot 22, and the twisted section 10d between the first and second bearing sections 11a and 11b will extend over five slots 22, as shown in Fig. 19 (a). By repeating the process described above, as in Fig. 20 (a) and (b), the first bearing portion 11a of the first coil 10 is supported on the outside of the first slot 22, while the second bearing portion 11b of the sixth coil 10 is supported on the inside of the first slot 22, as shown in Fig. 21 shown.

[0125] By repeating this process, most of the first and second support portions 11a and 11b of the coils 10 are supported in the slots 22, however, as shown in Fig. As shown in Fig. 21, the second bearing portions 11b, which are already supported in the inner sides of the 43rd slot 22 to the 48th slot 22, interfere with the first bearing portions 11a, which are to be supported on the outer sides of these slots 22. These second bearing portions 11b are therefore temporarily removed from the slots 22 so that the first bearing portions 11a can be inserted, and are then reinserted into the slots 22.

[0126] Although this last operation forms a boundary line 10B between the plurality of coils 10, as shown in Fig. 1 (a), this boundary line 10B is caused by the different interlacing modes between the coils 10 and is not related to, or the cause of, the above-mentioned problems of copper loss or protruding coil ends.

[0127] The Fig. The example shown in Figures 22 to 24 is a case where one coil is supported in one slot. In this case, unlike the aforementioned one-slot-two-coil method, there are no second support sections 11b already supported in the inner sides of the 43rd slot 22 to the 48th slot 22, which obstruct the first support sections 11a to be supported on the outer sides of these slots 22. Therefore, as shown in Fig. 22, no boundary line 10B is formed between the coils 10.

[0128] The armature 100, the coils 10 constituting the armature 100, and the method for mounting these coils 10 in the slots 22 of the core 20 can be expressed in terms of the following technical means 1 to 5. First, technical means 1 is as follows: "A coil 10 for an electromechanical device, wherein the coil 10 is to be mounted in the slots 22 between a plurality of teeth 21 of a core 20 for an electromechanical device that converts electrical energy and mechanical energy, wherein one or more windings 10A are wound to form the first and second support portions 11a and 11b to be supported in the slots 22 and the first and second coil ends 12a and 12b that are continuous between the first and second support portions 11a and 11b and arranged on the outside of the core 20, and wherein the windings 10A that form the first support portion 11a and the second support portion 11b are held by two holding means 30 in a state in which the alignment of the windings 10A is maintained, wherein when these two holding means 30 are rotated with respect to each other, in a state where the Alignment of the windings 10A,which form the first bearing portion 11a and the second bearing portion 11b, the twisted portion 10d can be formed in the first and second coil heads 12a and 12b, and the coil 10 can be mounted in the slots 22 between the teeth 21."

[0129] As in the Fig. As shown in Figures 2 to 5 or 20, the coil 10 according to the technical means 1 consists of one or more windings 10A wound by distributed winding and is held at two portions by two holding means 30. From the completion of the coil 10 and until it has been stored in a special slot 22, these holding means 30 maintain the alignment of the distributed wound windings 10A, in other words, prevent them from being wound up, thereby allowing deformation of the first and second coil ends 12a and 12b of the coil 10 until its storage without changing the shape of the first and second storage portions 11a and 11b.

[0130] The coil 10 is wound by distributed winding, as proposed in Japanese Unexamined Patent Application Publication No. 2009-195005, in which coils are wound over a plurality of slots and coils that are in phase or out of phase with each other are overlapped at the coil ends, and has first and second support portions 11a and 11b supported in two respective slots 22. As in Fig. 9 (a), between these first and second support portions 11a and 11b, the first and second coil ends 12a and 12b are exposed at the upper and lower sides of the drawing, respectively. Furthermore, as shown in the Fig. 2 (a) and Fig. 6, both ends of the windings 10A are projected from the coil 10 as connecting leads 10C for electrically connecting the coil 10 to another coil 10 or a power source.

[0131] The coil 10 according to the technical means 1 is manufactured according to the manufacturing method described later, with a basic structure in which one or more windings 10A are wound around a cylinder or frame, thereby forming the first and second support portions 11a and 11b to be supported in the slots 22 defined by the teeth 21, and the first and second coil ends 12a and 12b, which are continuous between the first and second support portions 11a and 11b and are arranged on the outside of the core 20. The first support portion 11a and the second support portion 11b of the coil 10 are held by two holding means 30 in a state in which the alignment of the windings 10A is maintained. Accordingly, these coils 10 enable the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires.

[0132] It is important that the portions of the coil 10 constituting the first and second support portions 11a and 11b are held by the support means 30 so that the alignment of the windings 10A is maintained. This is because, as will be stated later in the description of the method for mounting the coil 10 on the teeth 21, when a plurality of coils 10 are mounted on the teeth 21, in a case where a curved portion 10c is formed in the first and second coil heads 12a and 12b (i.e., when one coil is supported in a slot), or in a case where a twisted portion 10d is formed in the first and second coil heads 12a and 12b and the twisted portions 10d of each coil 10 overlap with each other (i.e.,When two coils are mounted in a slot, the first and second coil ends 12a and 12b of the first coil will naturally deform, allowing the first and second coil ends 12a and 12b of the next coil 10 to overlap without gaps. Accordingly, these coils 10 manufactured using the holding means 30 enable the following: (D) The fill factor of the coils in the slots can be increased. (When a coil is stored in a slot)

[0133] In this case, the first and second support portions 11a and 11b of the first distributed wound coil 10 are respectively supported in a first slot 22 and in another slot 22 separated from the first slot 22 by a certain distance, as shown in Fig. 24. A portion of, for example, the first coil head 12a will protrude towards the center where the rotor of the stator core 20 is to be supported, as shown in the Fig. 23 (c) and Fig. 22. At this time, however, a curved portion 10c is naturally formed on the lower side of the first coil head 12a, as shown in Fig. 23 (c).

[0134] A second coil 10 is mounted next to the first coil 10, and since a curved portion 10c, as shown in Fig. 23, is also formed in this second coil 10, this curved portion 10c is supported in the curved portion 10c of the first coil 10 without spaces. When subsequent coils 10 are mounted in this manner, the windings 10A of the coils 10 are mounted on the stator core 20 without spaces, resulting in the completion of a stator as shown in Fig. 22 (a) and (b), which allows the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device. (When two coils are stored in one slot)

[0135] In this case, as in Fig. 20 (a), the first and second support portions 11a and 11b of the first coil 10 are respectively supported in a first slot 22 and a second slot 22 separated from the first slot 22 by a certain distance, with the windings 10A constituting the first and second support portions 11a and 11b being in a wound state in the slots 22 at this time, thereby leaving space for inserting the first and second support portions 11a and 11b of the following coils 10 to be supported.

[0136] The actual insertion of the coils 10 into the stator core 20 is carried out by exerting an ejection force on the windings 10A, which form the first and second support sections 11a and 11b of the coils 10, in a direction orthogonal to the wire direction of the windings 10A. Furthermore, a projection is formed at each axial opening 23 of the stator core 20 to prevent inserted windings 10A from jumping out. In other words, if the stator core 20 is viewed from above, as exemplified in Fig. As shown in Figure 13 (a), the outer sides of the slots are wider than the openings.

[0137] When the first and second support portions 11a and 11b of the coil 10, held by the support means 30, are inserted through the narrow openings (axial openings 23) of such a stator core 20, the windings 10A must be inserted one by one in a direction orthogonal to the wire directions of the windings 10A. If round wire is used as the windings 10A, they can be supported with low friction and without resistance. In addition, since the coils 10 are wound by distributed winding, when entering the outer side, which is wider than the opening of the stator core 20, the windings 10A will naturally wind up in a direction orthogonal to the wire direction. As a result, the windings 10A in the stator core 20 are inserted into the outer side at a high density, which makes the use of round wire more advantageous.

[0138] Furthermore, in the Fig. 20 (a), a twisted portion 10d as shown in Fig. 9 (a) and (b), in the first and second coil ends 12a and 12b of the coil 10, this twisted portion 10d being formed by relative rotation of the holding means 30 in the Fig. 3 (a) by 180 degrees (to the state shown in Fig. 9 (b) shown state). At this time, the winding sections are twisted in ascending order so that, as shown in Fig. As shown in Fig. 23 (c), a space is formed around the first and second coil ends 12a and 12b of the first coil 10, in which the twisted portion 10d of a second coil 10 can be arranged in a tightly connected state. In other words, a next coil receiver 10e is formed.

[0139] By subsequently mounting the coils 10 in the same way, the windings 10A of the coils are mounted on the stator core 20 without spaces, resulting in the completion of a stator as shown in Fig. 1 (a) and (b), which can achieve the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device.

[0140] In both the case where one coil is stored in a slot and the case where two coils are stored in a slot, the distributed wound coils 10 are stored after being wound in the slots shown in Fig. 9 (b). In other words, considering a spool 10, the position of the first support portion 11a supported in the first slot 22 is on the opposite side with respect to the second support portion 11b supported in the second slot 22 separated from the first slot by a certain distance due to the twisted portion 10d of the spool 10.

[0141] In this state, that is, when the first support portion 11a and the second support portion 11b are located on opposite sides due to the twisted portion 10d of the coil 10, when the first portion of the windings 10A of the first support portion 11a, which is supported in the first slot 22, is located on the inside, as shown in Fig. 20 (a), the last portion of the windings 10A of the second support portion 11b, which is supported in the second slot 22 separated from the first slot by a certain distance, will be located on the outside of the second slot 22.

[0142] Generally, when a distributed-wound coil without a twisted section is supported in two slots, the first section of the windings of the first support section, supported in a first slot, and the last section of the windings of the second support section, supported in a second slot separated from the first slot by a certain distance, will be in the same position in each slot. Since the slots, both on the rotor side and the core side, are formed radially with respect to the center of the armature, the dimensions of their inner sides and the dimensions of their outer sides are different. Thus, when a distributed-wound coil without a twisted section is supported in two slots, the windings are supported in the same position, causing uneven inductance in the inner and outer windings (wires), resulting in an overall decrease in the coil's efficiency.The reason for this is that if an identical voltage is applied to the wires at the same time, a larger current will flow in the wires at lower inductance and this uneven inductance will work towards reducing the overall efficiency of the coil.

[0143] In the coil 10 according to this technical means, the presence of the twisted portion 10d means that, as exemplified in Fig. 9 (b) or Fig. 20 (a), when the first portion of the windings 10A of the first support portion 11a supported in a first slot 22 is located on the inside, the last portion of the windings 10A of the second support portion 11b supported in the second slot 22 separated from the first slot by a certain distance will be located on the outside of the second slot 22, thereby reducing or eliminating the uneven inductance in the parts (wires) of the coil 10, so that more magnetic flux is generated.

[0144] By reducing or eliminating the uneven inductance in the parts (wires) of the coil 10, the overall decrease in the efficiency of the coils 10 is prevented. As a result, the efficiency of an electromechanical device using these coils 10 can be improved, and the electromechanical device itself will have high output power and can be made smaller and lighter.

[0145] As described above, in the coil 10 according to the technical means 1, the presence of the twisted portion 10d reduces or eliminates uneven inductance in the parts (wires), resulting in an electromechanical device in which the coil 10 generally has high output power and can be made smaller and lighter. As a result, the coil 10 enables the following: (F) Uneven inductance in each winding can be compensated to increase coil efficiency.

[0146] Both in a case where one coil is stored in a slot and in a case where two coils are stored in a slot, the use of the coil 10 according to the technical means 1 enables the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires. (B) The manufacture and handling of the coils is easy. (C) Inserting the coils into the slots can be done easily. (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device. (F) The uneven inductance in each winding can be compensated to increase efficiency. (G) As a result, the armature can be made compact and efficient, and the electromechanical device can be easily manufactured.

[0147] Accordingly, the coil 10 according to the technical means 1 has no restriction on the cross-sectional shapes of the lead wires used for the construction of the coil, is easy to manufacture and handle, can be easily inserted into the slots and can have a high filling factor in the slots, and has small coil heads that allow high efficiency when used in an electromechanical device.

[0148] According to the technical means 2, in the coil 10 for electromechanical devices according to the above-mentioned technical means 1, "between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A constituting the coil, the radii of the loop winding portions formed by the windings 10A change gradually."

[0149] As in Fig. 2 or Fig. As shown in Figure 8, the coil 10 according to technical means 2 consists of one or more windings 10A distributed on a conical cylinder or a conical frame, and two sections of the coil are held by the holding means 30. During the period from the completion of the coil 10 until it is inserted into a specific slot of the core 20, these holding means 30 prevent the distributed wound windings 10A from unwinding and allow the deformation of the first and second coil ends 12a and 12b before storage without causing deformation of the first and second storage sections 11a and 11b. This is similar to technical means 1 described above.

[0150] In this coil 10, between a first radial section formed by a winding start section 10a and a second radial section formed by a winding end section 10b of the windings 10A forming the coil, the radii of the loop winding sections formed by the windings 10A change continuously or stepwise, as shown in the Fig. 2 (b) or Fig. 8. Furthermore, in this coil 10, the portions of the windings 10A forming the first and second support portions 11a and 11b are held by two holding means 30, so that the loop winding portions are kept sequentially aligned. The term "loop winding portion" here means a "loop" around the coil body of a winding 10A. Accordingly, this coil 10 enables the following: (B) The manufacture and handling of the coils are easy. (C) Inserting the coils into the slots can be done easily.

[0151] The coil 10 according to the technical means 2 is manufactured according to the manufacturing method described later, in which one or more windings 10A are distributedly wound around a conical cylinder or a conical frame, forming first and second support portions 11a and 11b to be supported in the slots 22 defined by the teeth 21, and first and second coil ends 12a and 12b that are continuous between the first and second support portions 11a and 11b and arranged on the outside of a core 20. The first and second support portions 11a and 11b of the coil 10 are held by two holding means 30 in a state in which the alignment of the windings 10A is maintained. Accordingly, this coil 10 enables the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires.

[0152] In this coil 10, it is important that the radii change gradually between the winding start portion 10a and the winding end portion 10b, and that, in order to maintain this state, the first and second support portions 11a and 11b are held by the holding means 30 in a state in which the alignment of the windings 10A is maintained, as described above.This is because, as described regarding the mounting method for mounting the coils 10 on the teeth 21, when a plurality of coils 10 are mounted on a plurality of teeth 21 and a curved portion 10c is formed in the first coil end 12a and the second coil end 12b, or when a twisted portion 10d is formed in the first coil end 12a and the second coil end 12b so that the twisted portions 10d of the coils 10 can overlap with each other, the first and second coil end 12a and 12b of the first coil itself will naturally deform, allowing the first and second coil end 12a and 12b of the next coil 10 to overlap without gaps. Accordingly, this coil 10 enables the following: (D) The fill factor of the coils in the slots can be increased.

[0153] Such coils 10 are then stored in slots 22 in the manner described below. (When a coil is stored in a slot)

[0154] In this case, the first and second support portions 11a and 11b of the first distributed wound coil 10 are each supported in a first slot 22 and in another slot 22 separated from the first slot 22 by a certain distance, as shown in Fig. 24. The curved portion 10c of, for example, the first coil head 12a will protrude towards the center where the rotor of the stator core 20 is to be supported, as shown in the Fig. 23 (c) and Fig. 24. At this time, however, since the radii gradually change between the winding start portion 10a and the winding end portion 10b of the coil 10, a curved portion 10c, in which the winding end portion 10b is the widest opening, is naturally formed on the lower side of the first coil end 12a, as shown in Fig. 21 (c).

[0155] A second coil 10 is mounted next to the first coil 10, and since a curved section 10c and a next coil receiver 10e, as in Fig. 23, are also formed in this second coil 10, the curved portion 10c and the next coil receiver 10e are stored in the curved portion 10c and the next coil receiver 10e of the first coil 10 without any spaces. If subsequent coils 10 are mounted in this manner, the windings 10A of the coils 10 are mounted on the stator core 20 without any spaces, resulting in the completion of a stator as shown in Fig. 22 (a) and (b), which enables the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device. (When two coils are stored in one slot)

[0156] In this case, as in Fig. 20 (a), the first and second support portions 11a and 11b of the first coil 10 are respectively supported in a first slot 22 and a second slot 22 separated from the first slot 22 by a certain distance, at which time the windings 10A constituting the first and second support portions 11a and 11b are in a wound state in the slots 22, thereby leaving space for inserting the first and second support portions 11a and 11b of the following coils 10 to be supported.

[0157] The actual insertion of the coils 10 into the stator core 20 is carried out by exerting an ejection force on the windings 10A, which form the first and second support sections 11a and 11b of the coils 10, in a direction orthogonal to the wire direction of the windings 10A. Furthermore, a projection is formed at each axial opening 23 of the stator core 20 to prevent inserted windings 10A from jumping out. In other words, if the stator core 20 is viewed from above, as exemplified in Fig. As shown in Figure 13 (a), the outer sides of the slots are wider than the openings.

[0158] When the first and second support portions 11a and 11b of the coil 10, held by the support means 30, are inserted through the narrow openings (axial openings 23) of such a stator core 20, the windings 10A must be inserted one by one in a direction orthogonal to the wire directions of the windings 10A. If round wire is used as the windings 10A, they can be supported with low friction and without resistance. In addition, since the coils 10 are wound by distributed winding, when entering the outer side wider than the opening of the stator core 20, the windings 10A will naturally wind up in a direction orthogonal to the wire direction. As a result, the windings 10A in the stator core 20 are inserted into the outer side at a high density, which makes the use of round wire more advantageous.

[0159] Furthermore, in the Fig. 20 (a), a twisted portion 10d as shown in Fig. 9 (a) and (b), in the first and second coil ends 12a and 12b of the coil 10, this twisted portion 10d being formed by relative rotation of the holding means 30 in the Fig. 3 (a) by 180 degrees (to the state shown in Fig. 9 (b) is formed). At this time, since the radii of the loop winding portions formed by the windings 10A gradually change between the first radial portion formed by the winding start portion 10a and the second radial portion formed by the winding end portion 10b of the windings 10A, in the twisted portion 10d, the winding portions are twisted in ascending order from the winding portion with the smallest radius to the winding portion with the largest radius, and a space is formed around the first coil end 12a and second coil end 12b of the first coil 10, in which a twisted portion 10d of a second coil 10 can be arranged in a closely connected state, as shown in FIGS. Fig. 9 and Fig. 20 (b) shown.

[0160] By subsequently mounting the coils 10 in the same way, the windings 10A of the coils are mounted on the stator core 20 without spaces, resulting in the completion of a stator as shown in Fig. 1 (a) and (b), which can achieve the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device.

[0161] Furthermore, in the Fig. 20 (a), a twisted portion 10d as shown in Fig. 9 (a) and (b), in the first and second coil ends 12a and 12b of the coil 10, wherein the twisted portion 10d is formed by relative rotation of the holding means 30 in the Fig. 3 (a) by 180 degrees (to the state shown in Fig. 9 (b) is formed). At this time, since the radii of the loop winding portions formed by the windings 10A gradually change between the first radial portion formed by the winding start portion 10a and the second radial portion formed by the winding end portion 10b of the windings 10A, in the twisted portion 10d, the winding portions are twisted in ascending order from the winding portion with the smallest radius to the winding portion with the largest radius, and a space is formed around the first coil end 12a and second coil end 12b of the first coil 10, in which a twisted portion 10d of a second coil 10 can be arranged in a closely connected state, as shown in FIGS. Fig. 9 and Fig. 20 (b) shown.

[0162] Both in the case where one coil is mounted in a slot and in the case where two coils are mounted in a slot, the use of the coil 10 according to the technical means 2 enables the following: (A) Both round wires and rectangular wires can be used as the lead wires forming the coils, without any restrictions on the cross-sectional shape of the wires. (B) The manufacture and handling of the coils are easy. (C) Inserting the coils into the slots can be done easily. (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device. (F) The uneven inductance in each winding can be compensated to increase efficiency. (G) As a result, the armature can be made compact and efficient, and the electromechanical device can be easily manufactured.

[0163] Accordingly, the coil 10 according to Technical Means 2 has no limitation on the cross-sectional shapes of the lead wires used for the construction of the coil, is easy to manufacture and handle, can be easily inserted into the slots, can have a high filling factor in the slots, and has small coil heads, which allow high efficiency when used in an electromechanical device.

[0164] Technical means 3 is as follows: "A method for manufacturing a coil 10 to be mounted in slots 22 between a plurality of teeth 21 of a core for an electromechanical device that converts electrical and mechanical energy, the method comprising the following steps: (a) winding one or more windings 10A around the circumference of a bobbin 40 in the shape of a cylinder or frame having two insertion grooves 41 to form first and second support portions 11a and 11b to be supported in the slots 22 and first and second coil ends 12a and 12b continuous between the first and second support portions 11a and 11b; (β) inserting a holding means 30 into each insertion groove 41 for holding the windings 10A forming the first and second support portions 11a and 11b while maintaining the alignment of the windings 10A; and (γ) Removing the coil 10 from the coil body 40 while holding the first bearing portion 11a and the second bearing portion 11b of the coil 10 with the holding means 30."

[0165] In step (α) of this manufacturing method, in an example described below, a coil former 40 as shown in Fig. 2 (b) or Fig. 8, wherein the coil body 40 is, for example, a conical cylinder, as in Fig. 2(b), where the diameter at the left end is the smallest and the diameter at the right end is the largest. Of course, this bobbin 40 may be a simple cylinder with a uniform diameter or a frame, in which case the frame may be conical, with one end being the smallest and the other end being the largest.

[0166] In addition, as in Fig. 2 (b) or Fig. 8, two insertion grooves 41 are formed in the coil former 40, into each of which one of the two plates constituting a holding means 30 is inserted. A plurality of these coil formers 40 are used in the actual manufacture of the coils 10, in which case the coil formers 40 are integrated in the axial direction, with the large-diameter ends forming pairs and the small-diameter ends forming pairs.

[0167] In this step α, one or more windings 10A, which are the essence of the coil 10, are wound around the circumference of the cylindrical or frame-shaped coil former 40. The winding of the windings 10A is practically performed by feeding the windings 10A, which are subjected to a predetermined tensile load, to the aforementioned integrated coil formers 40 while rotating the coil formers 40. Approximately four windings 10A are fed at a time.

[0168] Furthermore, when multiple coil formers 40 are integrated in the axial direction with the large-diameter ends forming pairs and the small-diameter ends forming pairs, multiple coils 10 can be formed simultaneously. In such a case, since the windings 10A are continuously supplied, connections of the windings 10A at the winding start portions 10a and winding end portions 10b, in other words, connecting wires 10C, can be formed between adjacent coils 10.

[0169] In this way, a coil 10 having a first support portion 11a and a second support portion 11b and a first coil head 12a and a second coil head 12b, which are continuous between the first and second support portions 11a and 11b, is formed on the coil body 40.

[0170] Next, in step (β), after inserting a part of the holding means 30 into the insertion grooves 41, as fictitiously shown in Fig. As shown in Figure 2 (b), the windings 10A forming the first bearing portion 11a and the second bearing portion 11b are clamped by the holding means 30. The windings 10A forming the first bearing portion 11a and the second bearing portion 11b are thus held parallel to each other by the holding means 30.

[0171] Then, in step (γ), the holding means 30 holds the first supporting portion 11a and the second supporting portion 11b of the windings 10A while the holding means 30 and the coil body 40 are moved with respect to each other, so that the coil 10 with the windings 10A constituting the first supporting portion 11a and the second supporting portion 11b held parallel to each other by the holding means 30 is removed and separated from the coil body 40.

[0172] Further, in this step (γ), when a plurality of coil bobbins 40 are integrated in the axial direction with the large-diameter ends forming pairs and the small-diameter ends forming pairs, a required number of coils 10 in which the winding start portions 10a and winding end portions 10b are connected can be formed by cutting the windings 10A at locations other than those between adjacent coils 10 to be connected at the winding start portions 10a and winding end portions 10b.

[0173] Accordingly, the manufacturing method according to the technical means 3 enables a very easy manufacture of a coil 10 which is easy to manufacture and handle, can be easily inserted into the slots and can have a high filling factor in the slots and has small coil heads which allow high efficiency when used in an electromechanical device.

[0174] Technical means 4 is as follows: "A method for mounting a coil 10 as described in technical means 1 or technical means 2 in slots 22 between a plurality of teeth 21 of a core for an electromechanical device that converts electrical and mechanical energy, the method comprising the following steps: (a) forming a curved portion 10c in the first and second coil heads 12a and 12b between the two holding means 30 holding a coil 10; (b) aligning the outlets 31 of the holding means 30 holding the coil 10 with the axial openings 23 of two respective slots 22 separated from each other by a specific distance; (c) pressing the first and second bearing portions 11a and 11b, held by the respective holding means 30, into the slots 22 through the outlets 31; and (d) inserting the next coil 10, in which a curved portion 10c is formed by the above steps (a) to (c), into the next slots 22 after the slots 22 in which the first coil 10 is mounted, so that the curved portion 10c of the next coil 10 is inserted into the curved portion 10c of the first coil 10, and repeating these steps."

[0175] This assembly method is intended to insert a coil 10 into each of a plurality of slots 22 between the teeth 21 of a core 20 for an electromechanical device to complete a stator, as shown in Fig. 22. In step (a), as shown in Fig. 24, a curved portion 10c is first formed in each of the first and second coil heads 12a and 12b between two holding means 30 holding the coil 10.

[0176] As a result, as in Fig. 23 (a) to (c), the first radial portion formed by the winding start portion 10a and the second radial portion formed by the winding end portion 10b of the windings 10A are stepped with respect to the holding means 30, and a curved portion 10c open at the second radial portion is formed between both the first and second coil ends 12a and 12b and the ends of the holding means 30, as shown in Fig. 23 (c). In this case, the curved portion 10c of, for example, the first coil end 12a will protrude toward the center where the rotor of the stator core 20 is to be supported, as shown in the Fig. 23 (c) and Fig. 24. At this time, however, since the radii gradually change between the winding start portion 10a and the winding end portion 10b of the coil 10, a curved portion 10c, in which the winding end portion 10b is the widest opening, is naturally formed on the lower side of the first coil end 12a, as shown in Fig. 23 (c).

[0177] When the spool 10 in which this curved portion 10c is formed is inserted, in step (b), the outlets 31 of the holding means 30 holding the first spool 10 are aligned with the axial openings 23 of two respective slots 22 separated from each other by a specified distance. Next, in step (c), the first and second bearing portions 11a and 11b held by the respective holding means 30 are pressed into the slots 22 through the outlets 31.

[0178] Then, in step (d), the next coil 10 in which a curved portion 10c is formed by the above steps (a) to (c) is inserted into the next slots 22 after the slots 22 in which the first coil 10 is mounted, so that the curved portion 10c of the next coil 10 is inserted into the curved portion 10c of the first coil 10.

[0179] If the second coil 10 is mounted directly next to the first coil 10, since the second coil 10 in this case also has a curved section 10c, as in Fig. As shown in Figure 23, this curved portion 10c is stored without spaces within the curved portion 10c of the first coil 10. Subsequent coils 10 are mounted in the same manner.

[0180] At this time, when the coils 10 are mounted on a stator core 20 as shown in the Fig. 23 (c) and Fig. As shown in Figure 24, the curved portions 10c of, for example, the first coil ends 12a protrude inward where the rotor of the stator core 20 is to be arranged, whereby the curved portions 10c are bent toward the opposite side in a next step. When the coils 10 are mounted on a rotor, the curved portions 10c of the first and second coil ends 12a and 12b do not need to be bent because they protrude toward the center.

[0181] As a result, the coils 10 and the windings 10A of the coils are mounted on the stator core 20 without spaces, resulting in the completion of a stator as shown in Fig. 22, which achieves the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device.

[0182] Accordingly, the technical means 4 simplifies the mounting of coils on the teeth of the stator core or rotor when a coil is stored in a slot, whereby the electromechanical device can be made compact, which simplifies the manufacture of the electromechanical device itself.

[0183] Finally, technical means 5 is as follows: "A method for mounting a coil 10 as described in technical means 1 or technical means 2 in slots 22 between a plurality of teeth 21 of a core for an electromechanical device that converts electrical and mechanical energy, the method comprising the following steps: (i) aligning the outlet 31 of the holding means 30 holding the first bearing portion 11a of the spool 10 with the axial opening 23 of a slot 22, and inserting the first bearing portion 11a into the slot 22; (ii) rotating the holding means 30 that holds the second support portion 11b of the spool 10 with respect to the holding means 30 that holds the first support portion 11a so that a rotated portion 10d is formed in the first and second spool heads 12a and 12b; (iii) aligning the outlet 31 of the other holding means 30, which holds the second bearing portion 11b of the spool 10, with the axial opening 23 of another slot 22, which is separate from the aforementioned slot 22, and inserting the second bearing portion 11b into the slot 22; and (iv) inserting a subsequent coil 10 into a slot 22 different from that in which the previous coil 10 is mounted, while a twisted portion 10d of the subsequent coil formed in steps (i) to (ii) overlaps the twisted portion 10d of the previous coil 10, and repeating these steps."

[0184] The assembly method according to the technical means 5 differs from that according to the technical means 4 and is, as in Fig. 20, intended for the insertion or assembly of the first bearing portion 11a of a first coil 10 and the second bearing portion 11b of a second coil 10 into a plurality of slots 22 of a rotor 20, whereby a stator, as shown in Fig. 1. In an initial step of this insertion or mounting of the coils 10, as shown in Fig. 20 (a), the first and second storage portions 11a and 11b of the first coil 10 are distributed and stored, respectively, in a first slot 22 and another slot 22 separated from the first slot 22 by a certain distance. At this time, the volume of the windings 10A of both the first and second storage portions 11a and 11b is half the volume of each slot 22, so that the windings 10A are located within the slots 22 in an unwound state. There remains enough free space in each slot with the first storage portion 11a or second storage portion 11b stored therein to accommodate the first storage portion 11a or second storage portion 11b of another coil 10 to be stored subsequently.

[0185] In step (i), the outlet 31 of the holding means 30 holding the first bearing portion 11a of the coil 10 is aligned with the axial opening 23 of a slot 22, and the bearing portion 11a is then inserted into the slot 22. If the second bearing portion 11b of another coil 10 has not yet been inserted into the slot 22 into which this first bearing portion 11a is to be inserted, the windings 10A constituting the first bearing portion 11a are stored in the slot 22 in a wound state, and by forcibly packing the second bearing portion 11b of another coil 10 into the slot 22, the first bearing portion 11a of the first coil 10 and the second bearing portion 11b of the following coil 10 are stored in a tightly connected state. This insertion is carried out with the holding means 30 and the ejection plate, which ejects the windings 10A from the holding means 30 in step (iii).

[0186] In step (ii), the holding means 30 holding the second bearing portion 11b of the spool 10 is rotated with respect to the holding means 30 holding the first bearing portion 11a, so that a rotated portion 10d, as exemplified in Fig. 9, in the first and second coil heads 12a and 12b. This twisted portion 10d is formed by relative rotation of the holding means 30 in the Fig. 3 (a) by 180 degrees (to the state shown in Fig. 9 (b) shown state).

[0187] When this twisted portion 10d is formed, the radii of the loop winding portions formed by the windings 10A change gradually between a first radial portion formed by a winding start portion 10a and a second radial portion formed by a winding end portion 10b of the windings 10A. Therefore, in the twisted portion 10d, the winding portions are twisted in ascending order from the winding portion with the smallest radius to the winding portion with the largest radius, and a space is formed around the first coil end 12a and second coil end 12b of the first coil 10, in which a twisted portion 10d of a second coil 10 can be arranged in a closely connected state, as shown in FIGS. Fig. 9 and Fig. 20 (b) shown.

[0188] Next, in step (iii), the outlet 31 of the other holding means 30 holding the second bearing portion 11b of the spool 10 is aligned with the axial opening 23 of another slot 22 separated from the above-mentioned slot 22, and the second bearing portion 11b is ejected from the holding means 30 through the ejection plate and inserted into the slot 22.

[0189] In step (iv), a subsequent coil 10 is inserted into a different slot 22 than the one in which the previous coil 10 is mounted, while a twisted portion 10d of the subsequent coil formed in steps (i) to (ii) overlaps the twisted portion 10d of the previous coil 10. This process is then repeated.

[0190] At this time, the center of the twisted portion 10d of the previous coil 10 is more constricted than the peripheral portions due to twisting, so that the peripheral portions of the twisted portion 10d are in an expanded state, so that a space is formed near the twisted portion 10d in which the twisted portion 10d of a subsequent coil 10 to be inserted into a subsequent slot 22 separated from the first slot 22 by a certain distance can be stored in a tightly connected state. In other words, the twisted portion 10d of the subsequent coil 10 is arranged so as to be intertwined with the twisted portion 10d of the previous coil 10, and once the insertion of the previous coil 10 and the adjacent subsequent coil 10 is completed, these twisted portions 10d will be in a tightly connected state.

[0191] In the stator core 20 constituting the electromechanical device, which is a motor, a generator, or the like, the plurality of slots 22 are formed in a circular shape with axial openings 23, the axial openings 23 communicating with the circular opening in which the rotor is to be mounted. Conversely, on the outer surface of a rotor to be mounted in the circular opening of a stator core 20, a plurality of slots 22 are formed in a circular shape with the axial openings 23 facing outward.

[0192] If two distributed wound coils 10 are to be inserted into such a plurality of slots 22 in a state where two coils are stored in one slot, there will naturally be cases where previously inserted coils 10 become obstructions in the last step. The last step is understood to be a step in which, when the first storage portions 11a of the first to seventh coils 10 are inserted in this order into the first to seventh slots 22, respectively, the second storage portions 11b of the last n ten up to n-6 ten Reel 10 in the last n ten up to n-6 ten Slot 22 can be inserted.

[0193] Thus, in the last step of the insertion process, with respect to a slot 22 into which the second bearing portion 11b is to be inserted, but a first bearing portion 11a of the previous spool 10 has already been inserted, the first bearing portion 11a is temporarily taken out, and the second bearing portion 11b of the next spool 10 is inserted and pressed into the outside of the slot 22, while the first bearing portion 11a is reinserted so that it is located on the inside.

[0194] In this way, when coils 10 are subsequently mounted, the windings 10A of the coils are mounted on the stator core 20 without spaces, resulting in the completion of a stator as shown in Fig. 1 (a) and (b), which can achieve the following: (D) The fill factor of the coils in the slots can be increased. (E) The coil heads can be reduced in size for use in an electromechanical device.

[0195] Therefore, according to the technical means 5, when two coils are stored in one slot, the mounting of the coils on the teeth of the stator core or rotor can be easily performed, and the electromechanical device can be made compact, thereby simplifying the manufacture of the electromechanical device itself.

Claims

[1] A pair of holding means 30 adapted to hold a coil 10 to be mounted in slots 22 between a plurality of teeth 21 of a core 20 for an electromechanical device that converts electrical and mechanical energy, each of the holding means 30 comprising: at least two base plates 32 which are openably coupled at one end; an outlet 31 formed between the other ends of the base plates 32, the outlet 31 being adapted to be aligned with an axial opening 23 of a slot 22; and a holding space 32a which is openable at the outlet 31 and which, when the base plates 32 close, holds windings 10A which form a first bearing portion 11a and a second bearing portion 11b of the coil 10, while maintaining the alignment of the windings 10A, wherein one holding means 30 of the pair of holding means 30 holds the first bearing portion 11a of the spool 10 and the other holding means 30 of the pair of holding means 30 holds the second bearing portion 11b of the spool 10, and wherein when the coil 10 is mounted in the slots 22, each holding space 32a communicates with an interior of the slot 22 through the axial opening via the holding means 30. [2] Holding means according to claim 1, wherein a stopper 31a is provided on at least one of the base plates 32 near the outlet 31 so that the windings 10A in the holding space 32a do not jump out. [3] Holding means according to claim 1 or 2, wherein the outlet 31 of each of the holding means 30 is provided with lips 36 which guide the coil 10 into the axial opening 23 of the slot 22.

Images