Winding structure of rotating electrical machine, method of forming the same, rotating electrical machine, and winding structure forming apparatus

Abstract

To provide a resin molding technique of a rotary electric machine winding capable of facilitating resin filling between coils, increasing the degree of resin filling between the coils, thereby improving the strength of the resin, and enhancing insulation performance.SOLUTION: (i), the rotating electrical machine winding structure 10 includes a plurality of magnet wire layers formed by the magnet wire W wound around the bobbin B, and the wound roving portion 2, and the roving portion 2 includes at least the inner roving portion 3 located on the inner side of the outermost layer that is the outermost magnet wire layer. As shown as a rotating electrical machine winding structure 10 ' in (ii), a plurality of inner roving portions 3 ' may be provided as roving portions 2 '.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a winding structure for a rotating electric machine, a method for forming the same, a rotating electric machine, and a winding structure forming device, and more particularly to a winding structure for a rotating electric machine that can form a high-strength mold for the winding. [Background technology]

[0002] In motor manufacturing, varnish is generally used to secure the magnet wire and resin molding is used to dissipate heat, but there is a need to improve the resonance frequency of the stator.To address this issue, epoxy resin containing glass filler or carbon filler is poured into the mold to increase strength.

[0003] FIG. 16 is an explanatory diagram showing the winding configuration of a rotating electric machine. In the figure, (p) is a perspective view of the bobbin, (q) is a side view of the winding structure, and (r) is a central cross-sectional view of the winding structure. FIG. 17 is a side cross-sectional view showing the configuration of a conventional rotating electric machine winding structure, in which (s) is a resin-molded configuration and (t) is a configuration using carbon fiber and resin molding. As shown in these figures, windings in rotating electric machines have traditionally been constructed by winding magnet wire W around a bobbin B and molding it with resin R at the end of the winding (FIG. 17(s)), or by winding carbon fiber C or the like around it and molding it with resin R at the end of the winding (FIG. 17(t)). Patent applications have been filed for resin-molding technology for windings, and the patent documents listed below are examples of such technology. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 02-256211 A "Method for manufacturing resin molded coils" [Patent Document 2] JP 2014-239614 A "Motor structure" [Patent Document 3] Japanese Utility Model Application Publication No. 63-038309 "Interlayer insulation of resin molded coils" [Patent Document 4] Japanese Patent Application Laid-Open No. 11-032459 "Rotor of a rotating electric machine and its manufacturing method" Summary of the Invention [Problem to be solved by the invention]

[0005] As mentioned above, resin molding generally involves pouring in epoxy resin containing glass filler or carbon filler to improve strength, but this filler increases the viscosity of the resin, making it difficult to fill the fine spaces between the coils. It also causes problems such as damage to the insulating coating, resulting in poor insulation. Furthermore, there is also the problem of insufficient fixation between the magnet wires that form the coil, resulting in vibration and magnetic noise when current is applied. Technology to resolve these issues is needed.

[0006] Therefore, the problem that the present invention aims to solve is to provide a resin molding technology that eliminates the problems of the conventional technology, makes it easier to fill the spaces between the coils with resin, and increases the degree of resin filling between the coils, thereby improving the strength of the resin and enhancing its insulating performance.

[0007] Another object of the present invention is to provide a resin molding technology that can more easily and firmly fix the magnet wires that form the coil, thereby suppressing the vibration of the coil and the generation of magnetic noise when a current is applied. [Means for solving the problem]

[0008] As a result of studying the above-mentioned problems, the inventors of the present application found that the problem could be solved by using high-strength roving as an aggregate for the resin mold and winding the roving so as to fill the gaps in the magnet wire wound around the bobbin, thereby firmly fixing the winding, and based on this, they were able to complete the present invention. That is, the invention claimed in this application, or at least the invention disclosed therein, as a means for solving the above-mentioned problems is as follows.

[0009] [1] A winding structure for a rotating electric machine, comprising a plurality of magnet wire layers wound around a bobbin and a wound roving section, characterized in that the roving section has at least an inner roving section located inside the outermost layer, which is the outermost magnet wire layer. [2] A winding structure for a rotating electric machine, comprising a plurality of magnet wire layers wound around a bobbin and a wound roving section, characterized in that the roving section has a surface roving section that covers the outermost layer, which is the outermost magnet wire layer, and an inner roving section that is located inside the outermost layer. [3] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that the inner roving portion has at least a deep layer roving wound inside the innermost layer, which is the innermost magnet wire layer, i.e., wound directly around the outer wall of the bobbin. [4] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that the inner roving portion has at least a middle layer roving wound outside the innermost layer, which is the innermost magnet wire layer. [5] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that the inner roving portion is a deep layer roving wound inside the innermost layer, which is the innermost magnet wire layer, i.e., directly around the outer wall of the bobbin, and a middle layer roving wound outside the innermost layer.

[0010] [6] The winding structure of a rotating electric machine according to either [1] or [2], characterized in that the roving portion has an in-coil filling structure in which it is wound so as to fill gaps in the coil made up of the multiple magnet wire layers. [7] The winding structure of a rotating electric machine according to [6], characterized in that the coil inner filling structure is an interlayer filling structure in which the magnet wire is wound so as to fill gaps occurring between the magnet wire layers. [8] The rotating electric machine winding structure according to [6], characterized in that the coil in-filling structure is an end filling structure in which the magnet wire layer is wound so as to fill gaps that occur at the ends of the magnet wire layer. [9] The winding structure of a rotating electric machine according to [6], characterized in that the roving portion includes a surface roving portion covering the outermost layer in addition to the inner roving portion, and the coil interior filling structure is a surface filling structure wound so as to fill in any irregularities in the surface roving portion.

[10] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that the roving portion is made of a high-strength material.

[11] The winding structure for a rotating electric machine according to

[10] , characterized in that the high strength material is at least one of a conductive high strength material and a non-conductive high strength material.

[0011]

[12] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that it is resin-molded.

[13] A winding structure for a rotating electric machine according to either [1] or [2], characterized in that it has a covering layer made of a resin-impregnated prepreg.

[14] The winding structure for a rotating electric machine according to either [1] or [2], characterized in that the roving portion has a self-fusing function and does not use resin.

[15] A rotating electric machine comprising the rotating electric machine winding structure according to either [1] or [2].

[16] A method for forming a winding structure for a rotating electric machine, comprising a magnet wire layer forming process for winding a magnet wire around a bobbin to form a plurality of magnet wire layers, and a roving portion forming process for winding a roving around a bobbin to form a roving portion, characterized in that the roving portion forming process is an inner roving portion forming process for forming an inner roving portion inside the outermost layer, which is the outermost magnet wire layer.

[17] A method for forming a winding structure for a rotating electric machine, comprising: A winding structure forming method comprising a magnet wire layer forming process of winding a magnet wire around a bobbin to form a plurality of magnet wire layers, and a roving section forming process of winding a roving around a bobbin to form a roving section, wherein the roving section forming process includes an inner roving section forming process of forming an inner roving section inside an outermost layer which is the outermost magnet wire layer, and a surface roving section forming process of covering the outermost layer after completion of the formation of the magnet wire layer.

[0012]

[18] The method for forming a winding structure according to either

[16] or

[17] , characterized in that the magnet wire layer forming process and the roving portion forming process are carried out simultaneously in parallel.

[19] The method for forming a winding structure according to either

[16] or

[17] , characterized in that at least one of the magnet wire layer forming process and the roving portion forming process is performed multiple times, and both processes are performed alternately.

[20] The method for forming a winding structure according to claim 16 or 17, characterized in that it comprises a resin treatment process in which the roving portion-formed body formed in the roving portion-forming process is impregnated with resin or covered with a prepreg impregnated with resin, and a hardening process in which the resin provided in the resin treatment process is hardened.

[21] The method for forming a winding structure according to either

[16] or

[17] , characterized in that the roving has a self-fusing function and does not require treatment with a resin.

[22] An apparatus for forming a winding structure for a rotating electric machine, comprising a magnet wire layer forming section for winding a magnet wire around a bobbin to form a plurality of magnet wire layers, and a roving section forming section for winding a roving around a bobbin to form a roving section, characterized in that the roving section forming section is configured to form an inner roving section inside an outermost layer which is the outermost magnet wire layer, and to cover the outermost layer after completion of the formation of the magnet wire layer to form a surface roving section. [Effects of the Invention]

[0013] The rotating electric machine winding structure, the method for forming the same, the rotating electric machine, and the winding structure forming device of the present invention are configured as described above, and therefore, a high-strength molded winding can be formed. That is, resin can be more easily filled between the coils, and the degree of resin filling between the coils can be increased. This improves the strength of the resin and its insulating performance. Furthermore, the magnet wires that form the coils can be more easily and firmly fixed, effectively suppressing vibration between the coils and magnetic noise when current is applied.

[0014] In the present invention, when a conductive, high-strength material, particularly carbon fiber, is used for the roving portion, this material has excellent thermal conductivity. Therefore, by wrapping and filling the gaps between the coils with carbon fiber, the heat from the coils can be quickly transferred to the motor case, resulting in excellent heat dissipation. This also contributes to suppressing the vibration between the coils and magnetic noise that occurs when current is applied to the coils. Furthermore, a resin mold using carbon fiber as the roving portion, i.e., CFRP, has a linear expansion coefficient that is much smaller than that of metals, making it possible to suppress breakage of the magnet wire due to thermal expansion and contraction.

[0015] Furthermore, according to the present invention, which uses a robin with self-fusing properties and does not use resin, it is possible to easily achieve strong fixation between coils, and also to reduce the amount of resin used, thereby contributing to the weight reduction of rotating electric machines.

[0016] It should be noted that the techniques disclosed in all of the above patent documents are methods of winding roving around the outer shell of a coil, and are not methods of providing an inner roving portion or winding roving so as to fill gaps in the coil simultaneously with the winding, as in the present invention. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a side cross-sectional view schematically showing a basic configuration of a winding structure for a rotating electric machine according to the present invention; [Figure 2] 10 is a side cross-sectional view schematically showing another basic configuration of a winding structure for a rotating electric machine according to the present invention. FIG. [Figure 3] 1 is a side cross-sectional view schematically showing the configuration of a rotating electrical machine winding structure of the present invention having deep layer lobbing. [Figure 4] 1 is a side cross-sectional view schematically showing the configuration of a rotating electric machine winding structure of the present invention having deep layer rovings and intermediate layer rovings. [Figure 5] 1 is a side cross-sectional view schematically showing the configuration of a rotating electrical machine winding structure of the present invention having an interlayer filling structure. [Figure 6] 1 is a side cross-sectional view schematically showing the configuration of a rotating electrical machine winding structure of the present invention having an end filling structure. [Figure 7] 1 is a side cross-sectional view schematically showing the configuration of a rotating electrical machine winding structure of the present invention having a surface filling structure. [Figure 8] 1 is a side cross-sectional view showing a first embodiment of a winding structure for a rotating electric machine according to the present invention. [Figure 9] FIG. 3 is a side cross-sectional view showing a second embodiment of the winding structure for a rotating electric machine according to the present invention. [Figure 10] 1 is a side cross-sectional view showing a schematic configuration of a winding structure for a rotating electric machine according to the present invention in terms of the material of the roving portion. [Figure 11] 1 is a side cross-sectional view schematically illustrating the configuration of a winding structure for a rotating electric machine according to the present invention in terms of the presence or absence of a resin treatment and the type of the resin treatment. [Figure 12] 1 is a flow chart showing a basic configuration of a method for forming a winding structure according to the present invention. [Figure 13] FIG. 10 is a flow chart showing another basic configuration of the winding structure forming method of the present invention. [Figure 14] FIG. 1 is a flow chart showing the configuration of a method for forming a winding structure of the present invention, including a resin treatment process. [Figure 15] 1 is a conceptual diagram showing the basic configuration of a winding structure forming apparatus according to the present invention. [Figure 16] FIG. 2 is an explanatory diagram showing a winding configuration in a rotating electric machine. [Figure 17] FIG. 10 is a side cross-sectional view showing the configuration of a conventional rotating electrical machine winding structure. DETAILED DESCRIPTION OF THE INVENTION

[0018] The present invention will be described in detail below with reference to the drawings. Fig. 1 is a side cross-sectional view showing a schematic diagram of the basic configuration of a rotating electric machine winding structure of the present invention. As shown in (i) of the figure, this rotating electric machine winding structure 10 is configured with multiple magnet wire layers made of magnet wire W wound around a bobbin B and a wound roving portion 2, and the roving portion 2 is mainly configured to have at least an inner roving portion 3 located inside the outermost layer, which is the outermost magnet wire layer. As shown in (ii) of the figure, a rotating electric machine winding structure 10' may have multiple inner roving portions 3' provided as roving portion 2'.

[0019] In the present rotating electric machine winding structure 10 and the like configured as described above, the roving portion 2 and the like includes one or more inner roving portions 3, 3', etc., provided at least inside the outermost layer, thereby forming a high-strength mold for the winding. That is, the ease and degree of resin filling between the coils is increased, improving the strength and insulating performance of the resin. In addition, the magnet wires that make up the coils are more easily and firmly fixed to each other, effectively suppressing vibration between the coils and the generation of magnetic noise when a current is applied.

[0020] Conventional methods for improving the strength of the resin and ensuring insulation include the method shown in Fig. 17 above, as well as a method of wrapping a sheet-like prepreg around the surface (outermost periphery) of the coil after winding. However, in the present invention, a roving portion 2 and the like are used, and by providing at least an inner roving portion 3 and the like, a structure can be realized in which the gaps in the magnet wire W wound around the bobbin B are filled. The roving portion 2 and the like function as aggregates for the resin mold.

[0021] Note that a roving material (hereinafter simply referred to as "roving"), which is a high-strength material, can be used to form the roving portion 2, etc. Roving is usually in the form of a thread or fiber wound around a roving bobbin, but because it has a smaller wire diameter than the magnet wire W, it can be inserted into the gaps between the magnet wires W. This makes it possible to improve strength in a smaller space. This also leads to a reduction in the amount of resin used in molding, contributing to the weight reduction of the entire rotating electric machine.

[0022] The specifications of the magnet wire W that is the subject of the rotating electric machine winding structure 10 of the present invention are not particularly limited, and it can be any of round wire, square wire, and rectangular wire, for example. Furthermore, the roving used to form the roving portion 2 can be one or more rovings that are bundled together and wound, but the number of rovings is not particularly limited.

[0023] 2 is a side cross-sectional view schematically showing another basic configuration of the rotating electric machine winding structure of the present invention. As shown in (i) of the figure, this rotating electric machine winding structure 210 is configured with multiple magnet wire layers made of magnet wire W wound around a bobbin B and wound roving portions 22, and the roving portions 22 mainly include surface roving portions 24 that cover the outermost layer, which is the outermost magnet wire layer, and inner roving portions 23 that are located inside the outermost layer. As shown in (ii) of the figure, a rotating electric machine winding structure 210' may have multiple inner roving portions 23' provided as roving portions 22'.

[0024] The rotating electric machine winding structure 210 and the like having such a configuration includes, as the roving portion 22, one or more inner roving portions 23, 23', etc., provided inside the outermost layer, as well as a surface roving portion 24, etc., and therefore forms a high-strength molded winding even better than the configuration shown in Figure 1. That is, the ease and degree of resin filling between the coils is further improved, further improving the strength and insulating performance of the resin. In addition, the magnet wires that make up the coils are more easily and firmly fixed to each other, further improving the suppression of vibration between the coils and magnetic noise when current is applied.

[0025] Figure 3 is a side cross-sectional view showing a schematic configuration of a rotating electric machine winding structure of the present invention having deep layer roving. As shown in (i) of the figure, this rotating electric machine winding structure 310 is characterized in that, in addition to the characteristic configurations shown in Figures 1 and 2 above, it has, as an inner roving portion 33, deep layer roving 35 that is wound at least inside the innermost layer, which is the innermost magnet wire layer, i.e., directly around the outer wall of the bobbin. As shown in (ii) of the figure, a rotating electric machine winding structure 310' may also have a surface roving portion 34' as a roving portion 32'.

[0026] The addition of deep roving 35 and the like to the configuration of the rotating electric machine winding structure of the present invention contributes to high-strength molding of the above-mentioned winding, facilitating resin filling between the coils, improving the strength and insulating performance of the resin, strengthening the fixation between the magnet wires, and strengthening the suppression of vibration and magnetic noise.

[0027] The inner roving portion constituting the winding structure of the rotary electric machine of the present invention can be configured to have at least a middle layer roving wound outside the innermost magnet wire layer, i.e., the innermost layer. The inner roving portion 3' in Fig. 1 is middle layer roving 36', and the inner roving portions 23, 23' in Fig. 2 are middle layer rovings 26, 26', respectively.

[0028] Figure 4 is a side cross-sectional view showing a typical configuration of a rotating electric machine winding structure of the present invention having deep layer rovings and intermediate layer rovings. As shown in (i) of the figure, this rotating electric machine winding structure 410 is characterized in that, in addition to the characteristic configurations shown in Figures 1 and 2 above, the inner roving portion 43 is formed of a deep layer roving 45 wound inside the innermost magnet wire layer, i.e., directly around the outer wall of the bobbin, and an intermediate layer roving 46 wound outside the innermost layer. As shown in (ii) of the figure, a rotating electric machine winding structure 410' may also have a surface roving portion 44' as a roving portion 42'.

[0029] The configuration in which the inner roving portion 43 etc. of the rotating electric machine winding structure of the present invention includes both the deep layer roving 45 etc. and the middle layer roving 46 etc. contributes to high-strength molding of the above-mentioned winding, facilitating resin filling between the coils, improving the strength and insulating performance of the resin, strengthening the fixation between the magnet wires, and strengthening the suppression of vibration and magnetic noise.

[0030] The roving portions 2, 22, etc. of the winding structure for a rotating electric machine of the present invention described with reference to the above drawings can be wound so as to fill gaps in a coil made up of multiple magnet wire layers, i.e., can have an in-coil filling structure. By winding the roving so as to fill the gaps in the magnet wire wound around the bobbin, the winding is firmly fixed. Specific examples of in-coil filling structures will be described below.

[0031] 5 is a side cross-sectional view that schematically illustrates the configuration of a rotating electric machine winding structure of the present invention that has an interlayer filling structure. As shown in the figure, the coil filling structure of this rotating electric machine winding structure 510 is an interlayer filling structure 57L that is wound so as to fill the gaps that occur between the magnet wire W layers. There is no limit to the number of gaps between the magnet wire W layers that are filled with the interlayer filling structure 57L, but it is desirable that as many gaps as possible be filled. This is because the winding is more firmly fixed. Most desirable is that all gaps between the layers are filled with the interlayer filling structure 57L.

[0032] 6 is a side cross-sectional view that schematically illustrates the configuration of a rotating electric machine winding structure of the present invention that has an end-filling structure. As shown in the figure, the coil-filling structure of this rotating electric machine winding structure 610 is an end-filling structure 67E that is wound so as to fill gaps that occur at the ends of the magnet wire W layer, i.e., radial gaps that occur between the bobbin B and the coil. As shown in the figure, it is desirable that the end-filling structures 67E be formed at both ends, as this will more firmly secure the winding.

[0033] 7 is a side cross-sectional view showing a schematic configuration of a rotating electric machine winding structure of the present invention having a surface filling structure. As shown in the figure, this rotating electric machine winding structure 710 includes, as roving portion 72, inner roving portion 73 and surface roving portion 74 that covers the outermost layer, and the coil's internal filling structure is a surface filling structure 77F that is wound so as to fill in any irregularities in surface roving portion 74. This configuration also contributes to more firmly fixing the winding.

[0034] 8 is a side cross-sectional view showing an embodiment (part 1) of the rotating electric machine winding structure of the present invention. As shown in the figure, the roving portion 82 of this rotating electric machine winding structure 810 is composed of an inner roving portion 83 and a surface roving portion 84, of which the inner roving portion 83 is composed of a deep layer roving 85 and a middle layer roving 86. The middle layer roving 86 also has an interlayer filling structure 87L. Furthermore, resin R is applied from above the surface roving portion 84, and the entire structure is molded.

[0035] 9 is a side cross-sectional view showing a second embodiment of the rotating electric machine winding structure of the present invention. As shown in the figure, the roving portion 92 of the rotating electric machine winding structure 910 of this example is composed of an inner roving portion 93 and a surface roving portion 94, of which the inner roving portion 93 is composed of a deep layer roving 95 and a middle layer roving 96. The middle layer roving 96 also has an interlayer filling structure 97L.

[0036] In addition, end filling structures 67E are formed at both ends of the coil. These can also be considered to be part of the inner roving portion 93. Furthermore, a surface filling structure 97F is provided on the surface roving portion 94 to fill in the unevenness. The roving used here has a self-fusing function, which will be described later, and is not treated with resin.

[0037] 10 is a side cross-sectional view showing a schematic configuration of the rotating electric machine winding structure of the present invention from the viewpoint of the material of the roving portion. As described above, roving, which is a high-strength material, can be used as the material of the roving portion, and at least one of a conductive high-strength material X8e such as carbon fiber (carbon roving) or a non-conductive high-strength material X8n such as glass fiber can be used.

[0038] The rotating electric machine winding structure X10 shown in FIG. 1(a) is an example in which all of the rovings constituting the roving section X2, which is made up of inner roving sections and surface roving sections, are made of conductive high-strength material X8e. The rotating electric machine winding structure X10′ shown in FIG. 1(b) is an example in which all of the rovings constituting the roving section X2′, which is made up of inner roving sections and surface roving sections, are made of non-conductive high-strength material X8n. The rotating electric machine winding structure X10″ shown in FIG. 1(c) is an example in which both the conductive high-strength material X8e and the non-conductive high-strength material X8n are used for the rovings constituting the roving section X2″, which is made up of inner roving sections and surface roving sections. In this way, either the conductive high-strength material X8e or the non-conductive high-strength material X8n can be used, or both can be used in combination.

[0039] When carbon fiber (carbon roving) is used as the conductive high-strength material X8e, it is molded into a resin to form CFRP (carbon fiber reinforced plastic), which has a linear expansion coefficient that is much smaller than that of metal, and can effectively prevent breakage of the magnet wire due to expansion and contraction caused by heat.

[0040] As the non-conductive high-strength material X8n, glass fiber, aramid fiber, etc. can be suitably used. These can be sufficient substitutes for carbon fiber. Furthermore, non-conductive high-strength material X8n, such as glass fiber and aramid fiber, has high insulating properties even when used alone, so a winding structure that combines strength and insulating properties can be obtained.

[0041] 11 is a side cross-sectional view showing a schematic configuration of a rotating electric machine winding structure of the present invention from the viewpoint of the presence or absence of resin treatment and the type of resin treatment. The rotating electric machine winding structure Y10 shown in FIG. 11(d) is resin-molded with resin R with the roving portion Y2 formed thereon. The rotating electric machine winding structure Y10' shown in FIG. 11(e) has the roving portion Y2' formed thereon and a covering layer P made of resin-impregnated prepreg provided thereon.

[0042] In the rotating electric machine winding structure Y10'' shown in FIG. 1(f), the roving portion Y2'' is formed from a roving having a self-fusing function, and no resin treatment is used. In this way, when a roving having a self-fusing function is used, there is no need to use resin to form the winding structure, which allows for space saving and weight reduction.

[0043] The rotating electric machine itself including the rotating electric machine winding structure 10 having any of the above-described configurations is also within the scope of the present invention.

[0044] 12 is a flow diagram showing the basic configuration of the method for forming a winding structure of the present invention. As shown in the figure, the method for forming a winding structure for a rotating electric machine includes a magnet wire layer forming process P10 in which magnet wire is wound around a bobbin to form multiple magnet wire layers, and a roving portion forming process P20 in which roving is wound around a bobbin to form a roving portion, and the roving portion forming process P20 mainly includes an inner roving portion forming process (P23) in which an inner roving portion is formed inside the outermost layer, which is the outermost magnet wire layer.

[0045] In the present method for forming a winding structure for a rotating electric machine having such a configuration, in the magnet-wire layer forming process P10, a magnet wire is wound around a bobbin to form multiple magnet-wire layers, while in the roving portion forming process P20, a roving is wound around a bobbin to form a roving portion. Here, the roving portion forming process P20 is an inner roving portion forming process P23, in which an inner roving portion is formed inside the outermost layer, which is the outermost magnet-wire layer, to form the rotating electric machine winding structure S10.

[0046] The magnet wire layer forming process P10 and the roving portion forming process P20 (P23) may be configured to be performed simultaneously in parallel, i.e., rather than one process being performed first and the other being performed later, the magnet wire layer and the roving portion are formed simultaneously in parallel.

[0047] On the other hand, at least one of the magnet wire layer forming process P10 and the roving portion forming process P20 (P23) may be divided into multiple steps, and the two processes may be performed alternately. That is, for example, a formation method of roving portion formation, magnet wire layer formation, roving portion formation, magnet wire layer formation, roving portion formation, magnet wire layer formation, . . .

[0048] 13 is a flow diagram showing another basic configuration of the method for forming a winding structure of the present invention. As shown in the figure, this method for forming a winding structure for a rotating electric machine includes a magnet wire layer formation process Q10 in which magnet wire is wound around a bobbin to form multiple magnet wire layers, and a roving portion formation process Q20 in which roving is wound around a bobbin to form a roving portion, and is characterized in that the roving portion formation process Q20 includes an inner roving portion formation process Q23 in which inner roving portions are formed inside the outermost layer, which is the outermost magnet wire layer, and a surface roving portion formation process Q24 in which the outermost layer is covered after the formation of the magnet wire layers is completed to form a surface roving portion.

[0049] In the present method for forming a rotating electric machine winding structure having such a configuration, in the magnet wire layer forming process Q10, magnet wire is wound around a bobbin to form multiple magnet wire layers, while in the roving portion forming process Q20, roving is wound around a bobbin to form a roving portion. In the roving portion forming process Q20, an inner roving portion is formed inside the outermost layer, which is the outermost magnet wire layer, in the inner roving portion forming process Q23, and after the formation of the magnet wire layer is completed, the outermost layer is covered to form a surface roving portion in the surface roving portion forming process Q24, thereby forming the rotating electric machine winding structure T10.

[0050] The magnet wire layer forming process Q10 and the roving portion forming process Q20 may be configured so that both processes are performed simultaneously in parallel, i.e., rather than one process being performed first and the other being performed later, the magnet wire layer and the roving portion are formed simultaneously in parallel.

[0051] On the other hand, at least one of the magnet wire layer forming process Q10 and the roving portion forming process Q20 may be divided into multiple steps, and the two processes may be performed alternately. That is, for example, a formation method such as roving portion formation, magnet wire layer formation, roving portion formation, magnet wire layer formation, roving portion formation, magnet wire layer formation, . . .

[0052] In any of the winding structure forming methods shown in FIGS. 12 and 13, the optimum method for forming a winding structure with higher strength is to wind the roving around the bobbin in advance, forming a deep-layer roving, forming the innermost magnet wire layer, forming a middle-layer roving, forming the next-layer magnet wire layer, forming the next-layer middle-layer roving, and so on, and then forming a roving layer so as to fill in the gaps each time the magnet wire layer (winding layer) changes.

[0053] Fig. 14 is a flow diagram showing the configuration of the method for forming a winding structure of the present invention, including a resin treatment process, etc. As shown in the figure, the method for forming a winding structure mainly comprises a resin treatment process P80 in which a roving-portion-formed body U09 formed in the roving portion formation process shown in Fig. 12 etc. is impregnated with resin or covered with a resin-impregnated prepreg, and a hardening process P90 in which the resin provided in the resin treatment process P80 is hardened.

[0054] In this winding structure forming method having such a configuration, in a resin treatment step P80, the roving portion-formed body U09 is impregnated with resin or covered with a resin-impregnated prepreg, and then in a hardening treatment step P90, the resin provided in the resin treatment step P80 is hardened to form the rotating electric machine winding structure U10. In the hardening treatment step P90, any suitable hardening method known in the art can be used, such as heat hardening or hardening by ultraviolet light irradiation.

[0055] When a roving having a self-fusing function is used, the resin treatment is not necessary, but such a winding structure forming method is also within the scope of the present invention.

[0056] 15 is a conceptual diagram showing the basic configuration of the winding structure forming apparatus of the present invention. As shown in the figure, the winding structure forming apparatus 1000 includes a magnet-wire layer forming section 500 that winds a magnet wire around a bobbin to form multiple magnet-wire layers, and a roving section forming section 800 that winds a roving around a bobbin to form a roving section, and the roving section forming section 800 is characterized by being configured to form an inner roving section inside the outermost layer, which is the outermost magnet wire layer, and to form a surface roving section by covering the outermost layer after the magnet-wire layer formation is completed.

[0057] According to the present winding structure forming apparatus 1000 having such a configuration, in the magnet wire layer forming section 500, magnet wire is wound around a bobbin to form multiple magnet wire layers, and in the roving section forming section 800, roving is wound around a bobbin to form a roving section, thereby forming a rotating electric machine winding structure.

[0058] In the roving portion forming section 800 of the winding structure forming apparatus 1000, inner roving portions are formed inside the outermost layer, and surface roving portions are formed by covering the outermost layer after the magnet wire layer has been formed. [Industrial Applicability]

[0059] The rotating electric machine winding structure, its forming method, rotating electric machine, and winding structure forming device of the present invention enable the formation of a high-strength mold for windings. This increases the degree of resin filling between the coils, improves the strength and insulating performance of the resin, and suppresses coil vibration and magnetic noise when current is applied. Therefore, this invention has high industrial applicability in the fields of manufacturing and using rotating electric machines, including AC servo motors and linear motors, and in all related fields. [Explanation of symbols]

[0060] 2, 2´, 22, 22´, 32, 32´, 42, 42´, 52, 62, 72, 82, 92, X2, X2´, X2´´, Y2, Y2´, Y2´´...Roving section 3, 3', 23, 23', 33, 33', 43, 43', 73, 83, 93...Inner roving section 10, 10´, 210, 210´, 310, 310´, 410, 410´, 410, 510, 610, 710, 810, 910, X10, X10´, X10´´, Y10, Y10´, Y10´´, S10, T10, U10...Rotating electric machine winding structure 24, 24´, 34´, 44´, 74, 84, 94...Surface roving section 26, 26', 36', 46, 46', 86, 96...Mid-rise roving 35, 35', 45, 45', 85, 95...Deep roving 57L, 87L, 97L…Interlayer filling structure 67E, 97E…End filling structure 77F, 97F…Surface filling structure 500...Magnet wire layer forming section 800...Roving forming section 1000...winding structure forming device B...Bobbin C...Carbon fiber P: Prepreg covering layer P10, Q10...Magnet wire layer formation process P20, Q20... Roving part formation process P23, Q23…Inner roving part formation process P80...Resin treatment process P90...hardening process Q24…Surface roving formation process R…Resin U09...Roving section formed body W...Magnet wire X8e…Conductive high strength material X8n...Non-conductive high strength material

Claims

1. A winding structure of a rotating electric machine, a plurality of magnet wire layers wound on a bobbin; The roving portion is wound around the spool. The roving portion has at least A rotating electric machine winding structure characterized in that there is an inner loving portion located inside the outermost layer, which is the outermost magnet wire layer.

2. A winding structure of a rotating electric machine, a plurality of magnet wire layers wound on a bobbin; The roving portion is wound around the spool. The roving portion has a surface roving portion covering the outermost layer, which is the outermost magnet wire layer; and A rotating electric machine winding structure characterized by having an inner roving portion located inside the outermost layer.

3. 3. The rotating electric machine winding structure according to claim 1, wherein the inner roving portion has at least a deep layer roving wound inside the innermost layer, which is the innermost magnet wire layer, i.e., wound directly around the outer wall of the bobbin.

4. 3. The rotating electric machine winding structure according to claim 1, wherein the inner roving portion has at least a middle layer roving wound outside the innermost layer, which is the innermost magnet wire layer.

5. 3. The rotating electric machine winding structure according to claim 1, wherein the inner roving portion comprises a deep layer roving wound inside the innermost layer, which is the innermost magnet wire layer, i.e., directly around the outer wall of the bobbin, and a middle layer roving wound outside the innermost layer.

6. 3. The winding structure of a rotating electric machine according to claim 1, wherein the roving portion has an in-coil filling structure in which the roving portion is wound so as to fill gaps in the coil made up of the plurality of magnet wire layers.

7. 7. The winding structure for a rotating electric machine according to claim 6, wherein the coil interior filling structure is an interlayer filling structure in which the magnet wire is wound so as to fill gaps occurring between the magnet wire layers.

8. 7. The winding structure for a rotating electric machine according to claim 6, wherein the coil inner filling structure is an end filling structure in which the magnet wire layer is wound so as to fill gaps occurring at the ends of the magnet wire layer.

9. 7. The rotating electric machine winding structure according to claim 6, wherein the roving portion includes a surface roving portion covering the outermost layer in addition to the inner roving portion, and the coil interior filling structure is a surface filling structure in which the coil is wound so as to fill in any irregularities in the surface roving portion.

10. 3. The winding structure for a rotating electrical machine according to claim 1, wherein the roving portion is made of a high-strength material.

11. 11. The winding structure for a rotating electric machine according to claim 10, wherein the high strength material is at least one of a conductive high strength material and a non-conductive high strength material.

12. 3. The winding structure for a rotating electrical machine according to claim 1, wherein said winding structure is resin-molded.

13. 3. The winding structure for a rotating electrical machine according to claim 1, further comprising a covering layer made of a resin-impregnated prepreg.

14. 3. The winding structure for a rotating electrical machine according to claim 1, wherein the roving portion has a self-welding function and is made of no resin.

15. A rotating electric machine comprising the rotating electric machine winding structure according to claim 1 or 2.

16. A method for forming a winding structure for a rotating electric machine, comprising: a magnet wire layer forming step of winding a magnet wire around a bobbin to form a plurality of magnet wire layers; The method includes a roving part forming process in which a roving part is formed by winding the roving around a bobbin, The roving portion forming process includes: The method for forming a winding structure is characterized by the step of forming an inner roving portion inside the outermost layer, which is the outermost magnet wire layer.

17. A method for forming a winding structure for a rotating electric machine, comprising: a magnet wire layer forming step of winding a magnet wire around a bobbin to form a plurality of magnet wire layers; The method includes a roving part forming process in which a roving part is formed by winding the roving around a bobbin, The roving portion forming process includes: an inner roving portion forming step of forming an inner roving portion on the inner side of the outermost layer which is the outermost magnet wire layer; The method for forming a winding structure is characterized in that after the formation of the magnet wire layer, there is a surface roving portion forming step for covering the outermost layer and forming a surface roving portion.

18. 18. The method for forming a winding structure according to claim 16, wherein the magnet wire layer forming step and the roving portion forming step are performed simultaneously in parallel.

19. 18. The method for forming a winding structure according to claim 16, wherein at least one of the magnet wire layer forming process and the roving portion forming process is performed multiple times, and both processes are performed alternately.

20. 18. The method for forming a winding structure according to claim 16, further comprising a resin treatment step of impregnating a roving portion-formed body formed in the roving portion forming step with a resin or covering the body with a prepreg impregnated with a resin, and a hardening treatment step of hardening the resin provided in the resin treatment step.

21. 18. The method for forming a winding structure according to claim 16, wherein the roving has a self-fusing function, and no treatment with a resin is required.

22. An apparatus for forming a winding structure for a rotating electrical machine, comprising: a magnet wire layer forming section that winds a magnet wire around a bobbin to form a plurality of magnet wire layers; The winding machine is configured to include a roving portion forming section that winds the roving around a bobbin to form a roving portion, The roving portion forming portion is An inner roving portion is formed inside the outermost layer, which is the outermost magnet wire layer, and The winding structure forming device is characterized in that it is configured to coat the outermost layer after the formation of the magnet wire layer is completed to form a surface roving portion.

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