Method and structure for winding rectangular wires

Abstract

To improve stability of windings by simple configurations.SOLUTION: A winding method of a rectangular wire 11 forms a coil 6 by winding the rectangular wire 11 around tooth parts 8 extending inside a motor radial direction from a yoke part 7 outside the motor radial direction, and winds the rectangular wire 11 in a state of inclining a width direction of the rectangular wire 11 to the motor radial direction when the rectangular wire 11 is wound around an inclined winding area 30 as an area of a part of the coil 6.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present disclosure relates to a method of winding a flat wire and a winding structure. and Winding structure Construction thereof.

Background Art

[0002] Generally, a brushless motor or the like composed of a rotor provided with a magnet and a stator around which a winding is wound can improve its performance as the density (occupation ratio) of the winding wound around the teeth of the stator is higher. Here, in order to increase the occupation ratio, a winding made of a so-called flat wire having a substantially rectangular cross section may be used. Since the flat wire can reduce the gap between windings in the stator compared with a round wire due to the characteristics of its shape, the occupation ratio can be further improved.

[0003] For example, Patent Document 1 discloses a technique of winding a flat wire formed from a round wire on the teeth portion of a split core.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, different from a round wire, a flat wire cannot be wound in a skein shape, so there is a risk that the flat wire may shift horizontally and unwind during winding. In addition, when winding a flat wire, the edge portion (corner portion) of the flat wire is likely to interfere with adjacent flat wires or the like, so it is difficult to perform stable winding.

[0006] Therefore, an object of the present disclosure is to provide a method of winding a flat wire and a winding structure capable of improving the stability when winding a flat wire. and Winding structure Construction thereof. [Means for solving the problem]

[0007] To solve the above problems, a first aspect of the present invention is a method for winding a flat wire to form a coil by winding a flat wire around a tooth portion extending radially inward from a radially outer yoke portion to a motor radially inward, wherein when winding the flat wire around a portion of the coil, the width direction of the flat wire is inclined with respect to the radial direction.

[0008] A second aspect of the present invention is a method for winding a rectangular wire according to the first aspect, wherein the portion of the coil is a region provided on at least one radial end side of at least one layer of the coil.

[0009] A third aspect of the present invention is a method for winding a rectangular wire according to the first or second aspect, wherein the portion of the coil is provided in a layer wound from one radial side to the other, and when winding the rectangular wire around the portion of the coil, the rectangular wire is wound in an inclined state such that one side of the rectangular wire is located closer to the teeth than the other side.

[0010] A fourth aspect of the present invention is a winding structure for a rectangular wire, comprising: an iron core having a yoke portion arranged radially outward and extending in the motor circumferential direction; a teeth portion extending radially inward from the intermediate portion of the yoke portion in the motor circumferential direction; and flange portions extending radially to both sides in the motor circumferential direction from the radially inner end of the teeth portion; and a coil formed by winding a plurality of layers of rectangular wire around the teeth portion, which is arranged in a slot partitioned by the yoke portion, the teeth portion, and the flange portion of the iron core, wherein the rectangular wire at least at one radial end of at least one layer of the coil has a width direction inclined with respect to the radial direction.

[0011] A fifth aspect of the present invention is a winding device for winding a rectangular wire around the teeth portion of an iron core, comprising: an iron core support portion capable of supporting the iron core; and a winding supply portion for supplying the rectangular wire to the iron core supported by the iron core support portion, wherein the winding supply portion is capable of tilting the rectangular wire in the circumferential direction of the rectangular wire. [Effects of the Invention]

[0012] According to this disclosure, it is possible to improve the stability when winding flat wire. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view of a motor to which a winding method and winding structure for flat wire according to one embodiment of the present invention are applied. [Figure 2] Figure 1 is a side view of the motor's segmented core, seen from the circumferential direction of the motor. [Figure 3] This is a cross-sectional view taken along the line III-III in Figure 2. [Figure 4] This is a schematic diagram showing the configuration of a winding device according to one embodiment of the present invention. [Figure 5] This is an explanatory diagram illustrating the movement of the nozzle. [Figure 6] This diagram illustrates the procedure for winding the first layer of rectangular wire onto the segmented core. [Figure 7] This diagram illustrates the procedure for winding the second layer of rectangular wire onto the segmented core. [Figure 8] This diagram illustrates the procedure for winding the third layer of flat wire onto the segmented core. [Figure 9] This diagram illustrates the procedure for winding the fourth layer of rectangular wire onto the segmented core. [Figure 10] This diagram illustrates the procedure for winding the fifth layer of flat wire onto the segmented core. [Modes for carrying out the invention]

[0014] Hereinafter, an embodiment of the present invention will be described based on the drawings. In each figure, X represents the axial direction of the motor (hereinafter referred to as the "motor axial direction"), Y represents the inner side in the radial direction of the motor (hereinafter referred to as the "motor radial direction"), and Z represents the circumferential direction of the motor (hereinafter referred to as the "motor circumferential direction").

[0015] FIG. 1 is a perspective view of a motor 1 to which a winding method and a winding structure of a flat wire according to an embodiment of the present invention are applied.

[0016] As shown in FIG. 1, the winding method and the winding structure of the flat wire according to the present disclosure are applied to, for example, a winding method and a winding structure of a flat wire of a stator 2 of a brushless motor 1 (rotating electric machine). The brushless motor 1 (hereinafter referred to as the "motor 1") has a stator 2 press-fitted into a housing (not shown) and a rotor 3 disposed inside the stator 2 in the motor radial direction and rotatably provided with respect to the stator 2.

[0017] The stator 2 includes a stator core (iron core) 4, an insulating insulator 5 (see FIGS. 2 and 3) attached to the stator core 4, and a coil 6. The stator core 4 of the present embodiment is a split core type stator core 4 divided in the motor circumferential direction, and is formed by annularly connecting a plurality of split cores (iron cores) 10 in the motor circumferential direction (Z direction).

[0018] FIG. 2 is a side view of the split core 10 of the motor 1 in FIG. 1 viewed from the motor circumferential direction. FIG. 3 is a cross-sectional view taken along the arrow III-III in FIG. 2. The arrows on the coil 6 in FIG. 3 indicate the direction in which the windings of each layer of the coil 6 are wound. The dashed-dotted line in FIG. 3 indicates the center line CL in the motor circumferential direction of the split core 10. In the following description, the inner side in the motor circumferential direction means the side of the center line CL in the motor circumferential direction of the split core 10, and the outer side in the motor circumferential direction means the direction away from the center line CL in the motor circumferential direction.

[0019] As shown in Figures 2 and 3, the segmented core 10 of the stator core 4 comprises a yoke portion 7 with a substantially arc-shaped cross-section extending in the motor circumferential direction on the outside in the motor radial direction (Y direction), a teeth portion 8 extending inward from the yoke portion 7 in the motor radial direction, and flange portions 9 extending from the inner end of the teeth portion 8 in the motor radial direction to both sides in the motor circumferential direction. In this embodiment, the segmented core 10 is formed, for example, by stacking multiple metal plates in the motor axial direction (X direction) and extends linearly along the motor axial direction. With the stator core 4 formed by connecting multiple segmented cores 10 in an annular manner in the motor circumferential direction, the yoke portion 7 constitutes a substantially cylindrical back yoke that forms an annular magnetic path. The coil 6 in this embodiment is formed by winding a flat wire 11 around the teeth portion 8. The segmented core 10 may have a skew angle that is inclined with respect to the longitudinal direction (motor axial direction) of the segmented core 10.

[0020] Connecting portions 7a and 7b are formed at both ends of the yoke portion 7 in the motor circumferential direction for connecting adjacent segmented cores 10. One connecting portion 7a extends in the motor axial direction, protruding outward in the motor circumferential direction. The other connecting portion 7b is formed in a groove shape, recessed inward in the motor circumferential direction, and extends in the motor axial direction, and is engageable with the one connecting portion 7a. By engaging the connecting portions 7a and 7b at both ends of the yoke portion 7 in the motor circumferential direction with the connecting portions 7b and 7a of the yoke portions 7 of other segmented cores 10 adjacent to each other in the motor circumferential direction, multiple segmented cores 10 can be connected to form a stator core 4.

[0021] The teeth portion 8 extends (projects) in the direction of the motor axis from the middle portion of the inner circumferential surface of the yoke portion 7 in the motor circumferential direction (approximately the center in this embodiment) toward the inside in the motor radial direction (towards the rotation center side of the motor 1). The sides 8a, 8a of the teeth portion 8 on both sides in the motor circumferential direction are arranged parallel to each other. In this embodiment, the inner surfaces 7c, 7c of the yoke portion 7 located on both sides of the teeth portion 8 in the motor radial direction are formed in a planar shape perpendicular to the motor radial direction. The inner surfaces 7c, 7c of the yoke portion 7 may be in a so-called overhanging state, such that they move inward in the motor radial direction as they move away from the teeth portion 8 toward the outside in the motor circumferential direction.

[0022] The flange portion 9 extends in the motor axial direction, extending (protruding) from the inner end of the tooth portion 8 in the motor radial direction to both sides in the motor circumferential direction. In this embodiment, the outer surfaces 9a, 9a of the flange portion 9 located on both sides of the tooth portion 8 in the motor radial direction are inclined with respect to a plane perpendicular to the motor radial direction, such that they move inward in the motor radial direction as they move outward from the tooth portion 8 in the motor circumferential direction.

[0023] On both sides of the tooth portion 8 in the motor circumferential direction, a pair of slots 12 for winding the flat rectangular wire 11 that forms the coil 6 are separated by the yoke portion 7, the tooth portion 8, and the flange portion 9. That is, the area inside the imaginary line (the dashed line L in Figure 3) connecting the motor circumferential end of the yoke portion 7 and the motor circumferential end of the flange portion 9 is the slot 12. In this embodiment, the pair of slots 12 expand inward in the motor radial direction as they move away from the tooth portion 8 in the motor circumferential direction, according to the inclination of the outer surfaces 9a, 9a of the flange portion 9.

[0024] The insulator 5 is mounted on the divided core 10 so as to cover the periphery of the teeth portion 8. The insulator 5 has two insulators 5a and 5b on both sides in the motor axis direction. The two insulators 5a and 5b are mounted on the divided core 10 so as to sandwich the teeth portion 8 from both sides in the motor axis direction. The insulator 5 covers the portion of the divided core 10 facing the slot 12 (the inner surfaces 7c, 7c of the yoke portion 7, the sides 8a, 8a of the teeth portion 8, and the outer surfaces 9a, 9a of the flange portion 9), and also covers the ends of the teeth portion 8 on both sides in the motor axis direction. Wall portions 13 and 14 are provided on the portion of the insulator 5 that covers the ends of the teeth portion 8 in the motor axis direction, protruding in the motor axis direction from both sides in the motor radial direction. Flat rectangular wire 11 forming the coil 6 is wound between the wall portions 13 and 14 on both sides of the insulator 5 in the motor radial direction. Two slits (not shown) are formed in the outer wall portion 13 of the insulator 5 on one side in the motor axial direction and in the motor radial direction, for engaging the winding start end 11a and the winding end 11b of the rectangular wire 11.

[0025] The rectangular wire 11 is a winding with a roughly rectangular cross-section, and multiple layers are wound around the teeth portion 8 of the divided core 10 from above the insulator 5, with the starting end 11a of the wire locked into a slit (not shown) in the wall portion 13 of the insulator 5. The rectangular wire 11 is inserted into one slot 12 of the divided core 10 and wound so that it passes between the walls 13 and 14 of the insulator 5 on one side of the teeth portion 8 in the motor axis direction, and is inserted into the other slot 12 of the divided core 10 and wound so that it passes between the walls 13 and 14 of the insulator 5 on the other side of the teeth portion 8 in the motor axis direction. After winding the rectangular wire 11, the ending end 11b of the rectangular wire 11 is locked into a slit (not shown) in the wall portion 13 of the insulator 5. In this embodiment, the rectangular wire 11 is wound so that it has 5 winding layers. The winding method of the rectangular wire 11 will be described later.

[0026] Next, a winding device 20 according to one embodiment of the present invention will be described. Figure 4 is a schematic diagram showing the configuration of the winding device 20 according to one embodiment of the present invention. Figure 5 is an explanatory diagram illustrating the movement of the nozzle 22, where (a) shows the state in the normal position, (b) shows the state in the inclined position on one side in the circumferential direction, and (c) shows the state in the inclined position on the other side in the circumferential direction. Note that Figure 5 shows the state of the nozzle 22 as viewed from the downstream side of the rectangular wire 11.

[0027] The winding device 20 is a device that forms a coil 6 by winding a flat wire 11 around the teeth portion 8 of the divided core 10. As shown in Figure 4, the winding device 20 includes a nozzle (winding supply unit) 22 that supplies the flat wire 11, which is fed from the reel 21 side in the direction of the white arrow, to the divided core 10 side, a winding machine 23 that winds the flat wire 11 supplied from the nozzle 22 onto the divided core 10, and a control unit 24.

[0028] The rectangular wire 11 may be a rectangular wire 11 that has been pre-formed into a roughly rectangular cross-section and wound onto the reel 21, or the round wire fed from the reel 21 may be processed and formed into a rectangular rectangular wire 11 before reaching the nozzle 22. For example, as shown by the dashed line in Figure 4, a forming machine 40 for processing and forming the round wire fed from the reel 21 into a rectangular wire 11 may be provided in the path between the reel 21 and the nozzle 22. In this embodiment, a stator core 4 is exemplified as the winding target, but the winding target is arbitrary and can also be applied to an armature core, etc. Furthermore, the present invention can also be applied when winding a coil on a non-magnetic material, and the function and application of the coil are arbitrary.

[0029] The winding machine 23 includes a core support section (iron core support section) 25 capable of supporting the divided core 10, a pair of guide members 26 for guiding the rectangular wire 11 into the slots 12 of the divided core 10, and a rotation mechanism 27 for rotating the core support section 25 and the pair of guide members 26. For example, the core support section 25 clamps the yoke section 7 of the divided core 10 from both sides in the motor circumferential direction. With the core support section 25 supporting the divided core 10, the divided core 10 can be rotated around a rotation axis extending along the motor radial direction. The rotation mechanism 27 is controlled by the control unit 24 to rotate the core support section 25 and the pair of guide members 26 together. Each guide member 26 is movable independently of each other in the motor circumferential direction and the motor radial direction relative to the divided core 10 supported by the core support section 25. Each guide member 26 moves in the motor circumferential direction and motor radial direction relative to the divided core 10 supported by the core support portion 25, guiding the rectangular wire 11 to a predetermined position in the slot 12 of the divided core 10.

[0030] As shown in Figures 4 and 5, the nozzle 22 supplies the rectangular wire 11 to the divided core 10 supported by the core support portion 25 of the winding machine 23. By rotating the divided core 10 with the rotation mechanism 27 of the winding machine 23, the rectangular wire 11 is drawn out from the nozzle 22 and wound onto the teeth portion 8 of the divided core 10. The nozzle 22 has a tilting mechanism 28 that can tilt in the circumferential direction of the rectangular wire 11 (hereinafter referred to as the "circumferential direction"). The tilting mechanism 28 is controlled by the control unit 24 to tilt the nozzle 22 in the circumferential direction. In this embodiment, the tilting mechanism 28 tilts the nozzle 22 in the circumferential direction about the center of the cross-section of the rectangular wire 11 as an axis. As the nozzle 22 tilts in the circumferential direction, the rectangular wire 11 supplied from the nozzle 22 also tilts in the circumferential direction. That is, the nozzle 22 is capable of tilting the rectangular wire 11 in the circumferential direction. The nozzle 22 is tiltable between a normal position (see Figure 5(a)) in which the rectangular wire 11 is supplied so that its width direction W is aligned with the motor radial direction of the divided core 10 supported by the core support portion 25, and inclined positions on both sides in the circumferential direction (see Figures 5(b) and 5(c)) in which the rectangular wire 11 is supplied so that its width direction W is inclined with respect to the motor radial direction of the divided core 10. The rectangular wire 11 supplied from the nozzle 22 is guided by a pair of guide members 26 to a predetermined position in the slot 12 of the divided core 10.

[0031] The timing for tilting the nozzle 22 can be determined by the operating state of the rotation mechanism 27 that rotates the core support portion 25 of the winding machine 23. In other words, the timing for tilting the nozzle 22 can be controlled by the rotation angle (number of rotations) of the segmented core 10 from the start of the winding operation. Since the rotation angle of the segmented core 10 is determined by the operation of the rotation mechanism 27, the control unit 24 that controls the rotation mechanism 27 can grasp the winding status of the winding in real time. For example, as shown by the arrows in Figure 3, the winding of the first layer of the rectangular wire 11 (the innermost layer in the motor circumferential direction) is completed by rotating the segmented core 10 approximately 8 times after the winding of the first layer of rectangular wire 11 has started, and then the winding of the second layer (the outermost layer of the first layer in the motor circumferential direction) is started. Similarly, the winding of the second and third layers is completed by rotating the segmented core 10 approximately 8 times, the fourth layer approximately 6 times, and the fifth layer approximately 2 times. As a result, the control unit 24 controls the nozzle tilting mechanism 28 to tilt the nozzle 22 at a desired timing based on the rotation angle of the divided core 10, which is recognized via the operating state of the rotation mechanism 27. The desired timing for tilting the nozzle 22 will be described later.

[0032] Next, the winding method for the rectangular wire according to this embodiment will be described. Figures 6 to 10 illustrate the procedure for winding the rectangular wire 11 onto the divided core 10, with Figure 6 showing the first layer, Figure 7 showing the second layer, Figure 8 showing the third layer, Figure 9 showing the fourth layer, and Figure 10 showing the fifth layer. In Figures 6 to 10, (a) shows the state at the start of winding, and (b) shows the state at the end of winding.

[0033] In Figures 6 to 10, the slot 12 located to the left of the teeth section 8 will be referred to as the left slot 12, and the slot 12 located to the right of the teeth section 8 will be referred to as the right slot 12. Also, in Figures 6 to 10, the guide member 26 located to the left of the teeth section 8 will be referred to as the left guide member 26, and the guide member 26 located to the right of the teeth section 8 will be referred to as the right guide member 26. Furthermore, in Figures 6 to 10, the lines connecting the rectangular wires 11 in the left and right slots 12 indicate that the rectangular wires 11 are continuous with each other. In the following explanation, the order in which the rectangular wires 11 are assigned indicates the order in which the rectangular wires 11 of each layer are wound onto the teeth section 8.

[0034] As shown in Figure 6, in this embodiment, the first layer of flat wire 11 of the coil 6 is wound from the outside to the inside in the motor radial direction of the left and right slots 12. When winding the first layer of flat wire 11, the left and right guide members 26 are inserted into the left and right slots 12. The tips of the left and right guide members 26 are positioned at a predetermined width inward in the motor radial direction from the insulator 5 that covers the inner surface 7c of the yoke portion 7 (the position of the left guide member 26 in Figure 6(a)). The predetermined width is set to a width that allows one flat wire 11 to be inserted (for example, a width slightly wider than the length W in the width direction of the flat wire 11). At this time, the tips of the left and right guide members 26 are spaced apart from the insulator 5 that covers the side surface 8a of the teeth portion 8.

[0035] The first flat wire 11 of the first layer is supplied with its winding start end 11a locked into the slit (not shown) of the insulator 5, and the nozzle 22 positioned in its normal location. Guided by the right-side guide member 26, it is inserted into the outer end (the end on the yoke 7 side) of the right-side slot 12 in the motor radial direction. Because the winding start end 11a of this first flat wire 11 of the first layer is locked into the slit of the insulator 5, it is difficult for it to shift laterally inward in the motor radial direction. After passing between the outer walls 13 and 14 of the insulator 5 in the motor axial direction, the flat wire 11 is guided by the left-side guide member 26 and inserted into the outer end (the motor radial direction) of the left-side slot 12, as shown by the white arrow in Figure 6(a). At this time, the right-side guide member 26 moves inward in the motor radial direction (to the position of the right-side guide member 26 in Figure 6(a)) so as to be separated by the predetermined width from the flat wire 11 that was just guided. Subsequently, the rectangular wire 11 passes between the outer walls 13 and 14 of the insulator 5 in the motor axis direction, and is then guided by the right-side guide member 26 and inserted into the second slot of the first layer of the right-side slot 12, as shown by the white arrow in Figure 6(a). At this time, the left-side guide member 26 moves inward in the motor radial direction so as to be separated from the rectangular wire 11 that was guided just before by the predetermined width. This operation is repeated, and the left and right guide members 26 are alternately moved inward in the motor radial direction by the predetermined width, while the rectangular wire 11 is wound around the second to seventh slots of the first layer. In this embodiment, the rectangular wires 11 from the first to the seventh slots of the first layer are supplied with the nozzle 22 held in its normal position. In other words, the first to seventh sections of the first layer of coil 6 are normal winding regions 29 in which the flat wire 11 is wound with the width direction W of the flat wire 11 aligned with the motor diameter direction (Y direction) of the divided core 10 (as shown by the dashed line in Figure 6(a)) (see Figure 6(b)). In the normal winding regions 29 of the first to seventh sections of the first layer of coil 6, the long side of the cross-section of the flat wire 11 is in surface contact with the insulator 5 that covers the side surface 8a of the teeth portion 8.

[0036] After winding the seventh flat wire 11 of the first layer, if the left and right guide members 26 are moved inward in the motor radial direction, the left and right guide members 26 will interfere with the flange portion 9 of the divided core 10. For this reason, as shown in Figure 6(b), when winding the eighth flat wire 11 of the first layer, the flat wire 11 is wound onto the teeth portion 8 without using the left and right guide members 26. The eighth flat wire 11 of the first layer is supplied with the nozzle 22 held in an inclined position. That is, as shown by the dashed line in Figure 6(b), the eighth of the first layer of the coil 6 is an inclined winding region (a part of the region) 30 in which the flat wire 11 is wound with its width direction W inclined with respect to the motor radial direction (Y direction) of the divided core 10 (hereinafter simply referred to as "the flat wire 11 inclined state"). Thus, the first inclined winding region 30 is provided as the eighth (inner end side in the motor radial direction) of the first layer. In this embodiment, when winding the flat wire 11, the eighth inclined winding region 30 of the first layer is wound in an inclined state such that the outer side of the flat wire 11 in the motor radial direction is located closer to the teeth portion 8 (inner side in the motor circumferential direction) than the inner side. In this embodiment, the inner corner of the flat wire 11 in the motor circumferential direction and the outer corner of the flat wire 11 in the motor radial direction (lower side in Figure 6) of the eighth inclined winding region 30 of the first layer contacts the insulator 5 that covers the side surface 8a of the teeth portion 8. Also, the inner corner of the flat wire 11 in the motor circumferential direction and the inner corner of the flat wire 11 in the motor radial direction (upper side in Figure 6) of the eighth inclined winding region 30 of the first layer is spaced apart from the insulator 5 that covers the side surface 8a of the teeth portion 8, and contacts the insulator 5 that covers the outer surface 9a of the flange portion 9.

[0037] Furthermore, when winding the flat wire 11 around the teeth portion 8, winding the flat wire 11 at an angle means that the state of the flat wire 11 when winding it is inclined with respect to the motor radial direction of the divided core 10. In other words, the width direction W of the flat wire 11 in the inclined winding region 30 of the coil 6 after winding may be inclined with respect to the motor radial direction, or it may be aligned with the motor radial direction.

[0038] As shown in Figure 7, the second layer of flat wire 11 of the coil 6 is wound from the inside to the outside in the motor radial direction of the left and right slots 12. The left and right guide members 26 are not used when winding the second layer of flat wire 11. The first flat wire 11 of the second layer is supplied by the nozzle 22 in the normal position and wound onto the teeth portion 8 so as to overlap the eighth flat wire 11 of the first layer (see Figure 7(a)). Subsequently, the second to eighth flat wires 11 of the second layer are supplied by the nozzle 22 in the normal position and wound onto the teeth portion 8 so as to overlap the seventh to first flat wires 11 of the first layer (see Figure 7(b)). In other words, as shown by the dashed lines in Figures 7(a) and 7(b), the first to eighth layers of the second layer of coil 6 are normal winding regions 29 in which the width direction W of the wound flat wire 11 is aligned with the motor radial direction (Y direction) of the divided core 10. The inner surface of the flat wire 11 of the second layer in the motor circumferential direction is in surface contact with the outer surface of the flat wire 11 of the first layer in the motor circumferential direction.

[0039] As shown in Figure 8, the third layer of flat wire 11 of the coil 6 is wound from the outside to the inside in the motor radial direction of the left and right slots 12. When winding the third layer of flat wire 11, the left and right guide members 26 are inserted into the left and right slots 12. Then, similar to the first layer, the flat wire 11 is wound from the 1st to the 7th face of the third layer while alternately moving the left and right guide members 26 inward in the motor radial direction by the predetermined width, and the flat wire 11 is wound on the 8th face without using the left and right guide members 26.

[0040] The first flat wire 11 of the third layer is supplied while the nozzle 22 is held in an inclined position. That is, the first of the third layer of the coil 6 is an inclined winding region 30 in which the flat wire 11 is wound in an inclined state (shown by a dashed line in Figure 8(a)) when the flat wire 11 is wound (see Figure 8(b)). The inclined winding region 30 of the third layer is provided at the first of the third layer (the outer end side in the motor radial direction). In this embodiment, when winding the flat wire 11, the first inclined winding region 30 of the third layer is wound in an inclined state such that the outer side of the flat wire 11 in the motor radial direction is located closer to the teeth portion 8 (inside in the motor circumferential direction) than the inner side. The inner and outer corners of the flat wire 11 in the motor circumferential direction (lower side in Figure 8) of the first inclined winding region 30 of the third layer contact the outer surface of the eighth flat wire 11 in the motor circumferential direction. Furthermore, the outer corners of the flat wire 11 in the first inclined winding region 30 of the third layer, both in the circumferential direction of the motor and in the radial direction of the motor (the lower side in Figure 8), are in contact with the insulator 5 that covers the inner surface 7c of the yoke portion 7.

[0041] The second to eighth rectangular wires 11 of the third layer are supplied with the nozzle 22 held in its normal position. That is, as shown by the dashed line in Figure 8(b), the second to eighth rectangular wires of the third layer of the coil 6 are a normal winding region 29 in which the rectangular wires 11 are wound with the width direction W of the rectangular wires 11 aligned with the motor radial direction (Y direction) of the divided core 10 (see Figure 8(b)). In the normal winding region 29 of the second to eighth rectangular wires of the third layer, the inner surface of the rectangular wire 11 in the motor circumferential direction makes surface contact with the outer surface of the rectangular wire 11 of the second layer in the motor circumferential direction.

[0042] As shown in Figure 9, the fourth layer of flat wire 11 of the coil 6 is wound outward in the motor radial direction from a position spaced outward from the flange 9 of the divided core 10 in the motor radial direction (in this embodiment, approximately the same position as the 6th or 7th of the third layer in the motor radial direction). In the fourth layer, when winding the first flat wire 11, the left and right guide members 26 are used to guide the flat wire 11 to a predetermined position before winding, while when winding the second to sixth flat wires 11, the flat wires 11 are wound without using the left and right guide members 26.

[0043] The first flat wire 11 of the fourth layer is supplied while the nozzle 22 is held in an inclined position. That is, the first of the fourth layer of the coil 6 is an inclined winding region 30 (see Figure 9(b)) in which the flat wire 11 is wound in an inclined state (shown by a dashed line in Figure 9(a)) when the flat wire 11 is wound. In this embodiment, the first inclined winding region 30 of the fourth layer is wound in an inclined state in which the inner side of the flat wire 11 in the motor radial direction is located closer to the teeth portion 8 (inner side in the motor circumferential direction) than the outer side. The inner corner of the flat wire 11 in the motor circumferential direction and the inner side in the motor radial direction (upper side in Figure 9) of the first inclined winding region 30 of the fourth layer contacts the outer surface of the flat wire 11 in the motor circumferential direction.

[0044] The second to fifth rectangular wires 11 of the fourth layer are supplied with the nozzle 22 held in its normal position. That is, the second to fifth rectangular wires of the fourth layer of the coil 6 are a normal winding region 29 (see Figure 9(b)) in which the rectangular wires 11 are wound with the width direction W of the rectangular wires 11 aligned with the motor radial direction (Y direction) of the divided core 10. In the normal winding region 29 of the second to fifth rectangular wires of the fourth layer, the inner surface of the rectangular wire 11 in the motor circumferential direction makes surface contact with the outer surface of the rectangular wire 11 of the third layer in the motor circumferential direction.

[0045] The sixth flat wire 11 of the fourth layer is supplied while the nozzle 22 is held in an inclined position. That is, the sixth of the fourth layer is an inclined winding region 30 in which the flat wire 11 is wound in an inclined state (shown by a dashed line in Figure 9(b)) when the flat wire 11 is wound. The inclined winding region 30 of the fourth layer is provided at the first (inner end side in the motor radial direction) and the sixth (outer end side in the motor radial direction) of the fourth layer. In this embodiment, when winding the flat wire 11, the sixth inclined winding region 30 of the fourth layer is wound in an inclined state such that the outer side of the flat wire 11 in the motor radial direction is located inward in the motor circumferential direction than the inner side. The inner surface of the flat wire 11 in the motor circumferential direction of the sixth inclined winding region 30 of the fourth layer is in surface contact with the outer surface of the flat wire 11 in the motor circumferential direction of the third layer.

[0046] As shown in Figure 10, the fifth layer of flat wire 11 of the coil 6 is wound from the outside to the inside in the motor radial direction of the left and right slots 12. When winding the fifth layer of flat wire 11, the left and right guide members 26 are inserted into the left and right slots 12. Then, similar to the first and third layers, the left and right guide members 26 are alternately moved inward in the motor radial direction by the predetermined width while winding the first and second layers of flat wire 11 of the fifth layer (see Figures 10(a) and 10(b)). The fifth layer of flat wire 11 is supplied while the nozzle 22 is held in its normal position. In other words, the first and second layers of the fifth layer of coil 6 are normal winding regions 29 (see Figure 10(b)) in which the flat wire 11 is wound with the width direction W of the flat wire 11 aligned with the motor radial direction (Y direction) of the divided core 10 (as shown by the dashed lines in Figures 10(a) and 10(b)). In the normal winding region 29 of the fifth layer, the inner surface of the flat wire 11 in the motor circumferential direction makes surface contact with the outer surface of the flat wire 11 of the fourth layer in the motor circumferential direction.

[0047] In the winding structure and winding method configured as described above, when winding the flat wire 11 in a portion of the coil 6 (inclined winding region 30), the flat wire 11 is wound with its width direction W inclined with respect to the motor radial direction. For example, as shown in Figure 6(b), in the eighth inclined winding region 30 of the first layer, the flat wire 11 is inclined when winding it. When winding the eighth flat wire 11, if an inward force (winding force) in the motor circumferential direction acts on the flat wire 11 with its corner contacting the teeth portion 8, an outward force in the motor radial direction (lower side in Figure 6(b)) is generated on the flat wire 11. Therefore, an outward force in the motor radial direction can be applied from the eighth flat wire 11 to the adjacent seventh flat wire 11, allowing the first to eighth flat wires 11 of the first layer to be brought into close contact with each other, improving the winding fixing force and enhancing the winding stability. Furthermore, the gaps between the rectangular wires 11 can be reduced, and the winding space can be increased.

[0048] Furthermore, in the eighth inclined winding region 30 of the first layer, the flat wire 11 is inclined when winding it. In this way, the flat wire 11 on the winding end side of the coil 6 layer is inclined, so even if the space between the seventh flat wire 11 of the first layer and the flange portion 9 of the divided core 10 is narrower than the width of the flat wire 11, interference between the edge (corner) of the eighth flat wire 11 and the seventh flat wire 11 can be avoided, and the eighth flat wire 11 can be inserted deeply into the space from the edge. As a result, the protrusion of the eighth flat wire 11 outward in the motor circumferential direction can be suppressed, and winding can be performed stably. In addition, the gap on the inside of the eighth flat wire 11 in the motor circumferential direction can be suppressed, and the winding space ratio can be increased.

[0049] Furthermore, as shown in Figure 8(a), in the first inclined winding region 30 of the third layer, when winding the rectangular wire 11, it is wound in an inclined state such that the outer side of the rectangular wire 11 in the motor radial direction is located closer to the teeth portion 8 than the inner side. When winding the first rectangular wire 11, if a force acts on the rectangular wire 11 in the motor circumferential direction with the corner of the rectangular wire 11 in contact with the second layer side, a force acts on the contacting corner of the rectangular wire 11 outward in the motor radial direction (lower side in Figure 6). In this way, by inclining the rectangular wire 11 at the beginning of the winding of the layer wound from the outside to the inside in the motor radial direction of the coil 6, a force can be applied to the first rectangular wire 11 outward in the motor radial direction, thereby suppressing winding collapse due to lateral displacement of the rectangular wire 11 in the motor radial direction and improving the stability of the winding.

[0050] Furthermore, as shown in Figure 9(a), in the first inclined winding region 30 of the fourth layer, when winding the rectangular wire 11, it is wound in an inclined state such that the inner side of the rectangular wire 11 in the motor radial direction is located closer to the teeth portion 8 than the outer side. When winding the first rectangular wire 11, if a force acts on the rectangular wire 11 in the motor circumferential direction with the corner of the rectangular wire 11 in contact with the third layer side, a force acts on the contacting corner of the rectangular wire 11 in the motor radial direction inward (upper side of Figure 9). In this way, by inclining the rectangular wire 11 at the beginning of the winding of the layer wound from the inside to the outside in the motor radial direction of the coil 6, a force can be applied to the first rectangular wire 11 in the motor radial direction, thereby suppressing winding collapse due to lateral displacement of the rectangular wire 11 outward in the motor radial direction, and improving the stability of the winding.

[0051] Furthermore, the inclined winding region 30 of the coil 6 is provided at the motor-radial end (inner end or outer end) of the coil 6 layer. In this way, the inclined winding region 30 of the coil 6 is provided at the motor-radial end of the coil 6, where winding collapse due to lateral displacement is likely to occur, thus effectively suppressing winding collapse due to lateral displacement.

[0052] Furthermore, in the winding device 20 configured as described above, the nozzle 22 that supplies the rectangular wire 11 to the divided core 10 supported by the core support portion 25 is capable of tilting the rectangular wire 11 in the circumferential direction. Therefore, when winding the rectangular wire 11 in areas where winding collapse due to lateral displacement of the divided core 10 is likely to occur, the rectangular wire 11 can be tilted, thereby improving the stability of the winding. In addition, when winding the rectangular wire 11 in areas where the space for inserting the rectangular wire 11 is narrow, the rectangular wire 11 can be tilted, which suppresses interference of the edges of the rectangular wire 11 with adjacent rectangular wires 11, etc., and suppresses the protrusion of the rectangular wire 11 outward in the circumferential direction of the motor, enabling stable winding.

[0053] Thus, according to this embodiment, the stability when winding the rectangular wire 11 can be improved by a simple configuration in which the rectangular wire 11 is tilted when winding the rectangular wire 11 around the teeth portion 8.

[0054] In this embodiment, the inclined winding region 30 of the coil 6 is provided on both ends of the coil 6 in the motor radial direction, but it is not limited to this, and the inclined winding region 30 of the coil 6 only needs to be provided on at least one end of the coil 6 in the motor radial direction.

[0055] Furthermore, in this embodiment, the inclined winding region 30 of the coil 6 is provided in multiple layers of the coil 6, but this is not limited to this, and the inclined winding region 30 of the coil 6 only needs to be provided in at least one layer of the coil 6.

[0056] Furthermore, in this embodiment, the flat wire winding method, winding structure, and winding device according to the present disclosure were applied to the flat wire winding method, winding structure, and winding device of motor 1, but the invention is not limited thereto and may be applied to the flat wire winding method, winding structure, and winding device of other rotating electric machines. For example, it may be applied to the flat wire winding method, winding structure, and winding device of an alternator (generator), etc.

[0057] Although the present invention has been described above based on the above embodiments, the present invention is not limited to the contents of the above embodiments, and can naturally be modified as appropriate without departing from the present invention. In other words, all other embodiments, examples, and operational techniques made by those skilled in the art based on these embodiments are of course included in the scope of the present invention. [Explanation of Symbols]

[0058] 1: Motor 4: Stator core (iron core) 6: Coil 7: York 8: Teeth Department 9: Tsuba (guard) 10: Split core (iron core) 11: Flat rectangular line 12: Slot 20: Winding device 22: Nozzle (winding supply unit) 25: Core support section (iron core support section) 30: Inclined winding area (partial area)

Claims

1. A method for winding a flat wire to form a coil by winding a flat wire around a tooth portion extending radially inward from a radially outer yoke portion, When winding the flat wire in the normal winding region, which is the area excluding the starting and ending ends of the coil layer, the flat wire is wound with its width direction aligned with the radial direction. When winding the rectangular wire around the inclined winding region, which is a part of the coil layer that is at the end of the winding process, the rectangular wire is wound with its width direction inclined relative to the radial direction. A method for winding rectangular wire, characterized by the features described above.

2. The portion of the coil is a region provided on at least one radial end side of at least one layer of the coil. The winding method for a rectangular wire according to feature 1.

3. The aforementioned portion of the coil is provided in a layer wound radially from one side to the other. When winding the rectangular wire around a portion of the coil, the rectangular wire is wound at an angle such that one side of the rectangular wire is positioned closer to the teeth than the other side. A method for winding a rectangular wire according to claim 1 or 2.

4. An iron core having a yoke portion positioned radially outward and extending in the motor circumferential direction, a teeth portion extending radially inward from the middle portion of the yoke portion in the motor circumferential direction, and flange portions extending radially inward from the inner end of the teeth portion to both sides in the motor circumferential direction, The device comprises a coil, which is arranged in a slot partitioned by the yoke portion, the teeth portion, and the flange portion of the iron core, and is formed by winding multiple layers of flat wire around the teeth portion, In the normal winding region, which is the area excluding the starting and ending ends of the coil layer, the width direction of the flat wire is aligned with the radial direction. In the inclined winding region, which is a part of the coil layer that is at the end of the winding process, the width direction of the flat wire is inclined with respect to the radial direction. A winding structure for flat rectangular wire characterized by the following features.

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