ROTATING ELECTRIC MACHINE HAVING A COIL ELEMENT AND METHOD FOR MANUFACTURING THE COIL ELEMENT

专利摘要:
In a rotating electrical machine, a field coil element comprises a first profile coil composed of a plurality of coaxially arranged coils. Coaxially arranged coils are wound around the outer periphery of the first pole core. The field coil element comprises a second profile coil composed of a plurality of coaxially arranged coils. The coaxially arranged coils are wound around the outer periphery of the second pole core. The field coil element comprises a connecting portion connecting the first profile coil and the second profile coil in series. A coil of the first and second profile coils has a first coil end extending therefrom to intersect the portion thereof at a portion thereof. The crossing portion between the first coil end and the connecting portion is arranged not to overlap with the turns of the first coil of the first and second profile coils.
公开号:FR3050082A1
申请号:FR1753176
申请日:2017-04-11
公开日:2017-10-13
发明作者:Youichi Hasegawa；Tomoya Imanishi
申请人:Denso Corp；
IPC主号:

专利说明:

ROTATING ELECTRIC MACHINE HAVING A COIL ELEMENT AND METHOD FOR MANUFACTURING THE COIL ELEMENT
FIELD OF THE INVENTION
The present invention relates to rotating electrical machines, such as generators and motors, comprising a rotor and a stator of which at least one is composed of a coil element; this coil element is formed with at least one profile coil element. The present invention also relates to methods of manufacturing such a coil element.
BACKGROUND OF THE INVENTION
U.S. Patent Publication No. 4,446,393 corresponding to Japanese Examined Patent Publication (kokoku) No. H024-049,336 and Japanese Unexamined Patent Publication No. 2006-271,121 disclose field coils. conventional formed each by winding in profile a rectangular connecting wire.
An example of methods for manufacturing a pair of first and second field coil elements to be used for producing a field coil assembly, which is described in the US patent publication and / or non-patent publications. Examined from Japan will be described hereinafter with reference to Figures ISA-18F and 19A-19F.
As illustrated in FIG. 1A, to produce the first field coil element, a first continuous rectangular link wire 100 having a predetermined length suitable for producing a first field coil element and a pair of first and second coil arrays 110a. and 110b are prepared.
Each of the first and second coils 110a and 110b has a round rectangular cylindrical shape. The rectangular connecting wire 100 has a thickness substantially less than the width of its main sides 100a.
A first small side of a first end portion of the connecting wire 100 is contacted on the periphery of the first coil reinforcement 110a so as to leave its predetermined elongate end Ta. The first small side of the first end portion of the connecting wire 100 is clamped by a clamping mechanism of the first bobbin reinforcement 110a.
Similarly, the other small side of the other end of the connecting wire 100 is contacted on the periphery of the second coil reinforcement 110b so as to leave its predetermined elongate end Tb. The other small side of the other end portion of the connecting wire 100 is clamped by a clamping mechanism of the second bobbin reinforcement 110b.
Then, as illustrated in FIG. 18B, the first and second coil armatures 110a and 110b are respectively rotated on their central axes 180 degrees in a predetermined direction, for example counterclockwise in FIG. 18B, as they come closer to each other under the effect of the connecting wire 100 which is under tension.
This allows the first and the other end portions of the connecting wire 100 to be wound in profile on the peripheries of the first and second coil frames 110a and 110b.
Then, as illustrated in FIG. 18C, the first and second coil armatures 110a and 110b are respectively rotated on their central axes at 90 degrees in the counterclockwise direction so that each of the start ends Ta and Tb of the connecting wire 100 cross on a first of the long sides 100a of the connecting wire 100. This forms a first turn (first layer) wound in profile around a corresponding first periphery among the peripheries of the first and second coils 110a and 110b.
After that, a predetermined number of rotations of the coils 110a and 110b in the counterclockwise direction is executed.
In particular, the execution of the predetermined number of rotations of the coils 110a and 110b allows the connecting wire 100 to be wound at their small sides (at their edges) on the outer peripheries of the first and second reinforcement 110a and 110b coils from the first and the other end of the wire 100 to the center thereof.
This forms successive turns of the connecting wire 100 wound in profile around the first and second coils 110a and 110b, respectively. The successive loops start from the remaining center of the connecting wire 100 by moving away along the axial directions of the first and second coil frames 110a and 110b (see Figures 18D and 28E).
After completion of the predetermined number of rotations of the coils 110a and 110b, a pair of spaced coil members connected to each other by a connecting portion 120 is generated (see Fig. 18E).
The pair of coil members is bent at the connecting portion 120 so that the spaced coil members are approaching each other and the leading ends Ta and Tb of the connecting wire 100 are substantially parallel to one another (see FIG. refer to Figure 18F). Removal of the pair of coil elements from the first and second coil frames 110a and 110b provides a first field coil element 130 consisting of a pair of series connected profile coils 130a and 130b. The beginning end Ta of the series connected profile coil 130a serves as a coil end thereof extending outwardly from a portion of the first turn of the coil 130a in a direction orthogonal to its direction. axial. Similarly, the start end Tb of the series connected profile coil 130b serves as a coil end thereof extending outwardly from a corresponding portion of the first turn of the coil 130b in a coil. direction orthogonal to its axial direction.
In addition, as illustrated in FIG. 19A, to produce the second field coil element, the identical connecting wire 100 and the first and second identical cylindrical coil reinforcements 110a and 110b are prepared,
In the first different point of manufacturing the second field coil element from the first field coil element, the other small side of the first end portion of the connecting wire 100 is contacted on the periphery of the field coil element. first bobbin reinforcement 110a so as to leave its beginning end Ta. The other small side of the first end portion of the connecting wire 100 is clamped by the clamping mechanism of the first coil reinforcement 110a.
In addition, the first small side of the other end of the connecting wire 100 is contacted on the periphery of the second coil reinforcement 110b so as to leave its leading end Tb. The first small side of the other end portion of the connecting wire 100 is clamped by the clamping mechanism of the second coil reinforcement 110b.
Then, in the second different point, as illustrated in FIG. 19B, the first and second coil armatures 110a and 110b are respectively rotated on their central axes at 180 degrees in a predetermined direction opposite to the counterclockwise direction, for example clockwise in Fig. 19B, as they come closer under the effect of the connecting wire 100 which is subjected to a voltage.
In this way, as for the first field coil element, the same predetermined number of rotations of the coil arches 110a and 110b in the clockwise direction is executed.
In particular, the execution of the same predetermined number of rotations of the coil reinforcements 110a and 110b allows the connecting wire 100 to be wound at their small sides (at their edges) on the outer peripheries of the first and second reinforcement. of coils 110a and 110b from the first and from the other ends of the connecting wire 100 towards the center thereof.
This forms successive turns of the connecting wire 100 wound in profile around the first and second coils 110a and 110b, respectively. The successive loops start from the remaining center of the connecting wire 100 by moving away along the axial directions of the first and second coils 110a and 110b (see Figures 19C to 19E).
After completion of the predetermined number of rotations of the bobbins 110a and 110b, a pair of spaced coil members connected to each other by a link portion 120 is generated (see Fig. 19E).
The pair of coil elements is bent at the connecting portion 120 so that the spaced coil members come together and the leading ends Ta and Tb of the connecting wire 100 are substantially parallel to each other. other (see Figure 19F). Removal of the pair of coil elements from the first and second coil frames 110a and 110b provides a second field coil element 140 consisting of a pair of series connected profile coils 140a and 140b. The beginning end Ta of the serially connected profile coil 140a serves as a coil end thereof extending outwardly from a first portion of the first turn of the coil 140a in a direction orthogonal to its axial direction. Similarly, the start end Tb of the series connected profile coil 130b serves as a coil end thereof extending outwardly from a corresponding portion of the first turn of the coil 130b in a coil. direction orthogonal to its axial direction.
As illustrated in Figs. 18F and 19F, assuming that the first field coil element 130 and the second field coil element 140 are disposed across a line, so that coil 130a and coil 140b are opposed 1 to each other, the first field coil element 130 and the second field coil element 140 are symmetrical with respect to this line.
SUMMARY OF THE INVENTION As an example of field coil assemblies for rotating electrical machines, such as DC motors, a set of field coils 200 configured through the use of the prime pair and second field coil members 130 and 140 is illustrated in Fig. 20A.
In particular, the set of field coils 200 is composed of a yoke assembly 210. The yoke assembly 210 consists of a yoke 215 which has substantially a ring shape and four pole cores 220.
The yoke 215 has an annular outer periphery and an annular inner periphery 215a which faces it.
The four pole cores 220 are mounted on the inner periphery 215a of the yoke 215 at substantially regular intervals. Note that FIG. 20A is a developed view of the inside of the yoke 215 of the field coil assembly 200 in a circumferential direction thereof.
Each of the four pole cores 220 is configured to protrude radially from the inner periphery 215a of the yoke 215 so as to have a substantially rounded rectangular cylindrical shape. Each of the four pole cores 220 is formed at its projecting end with a flange 221 for supporting one of the first and second field coil members 130 and 140.
The first field coil element 130 is installed in any two of the four pole cores 220 circumferentially adjacent to each other, and the second field coil element 140 is installed on the remaining two of the four pole cores 220. .
In particular, the series-connected profile coil 130b of the first field coil element 130 is mounted from its last layer on the periphery of the left-side core (circumferentially outside) of the two pole cores 220 on the Figure 20A.
Simultaneously with the mounting of the coil 130b on the left side core of the two pole cores 220, the series connected profile coil 130a of the first field coil element 130 is mounted from its last layer on the periphery of the core of the coil. right side (circumferentially inside) of the two pole cores 220 in FIG. 20A.
Like the first field coil element 130, the series connected profile coil 140b of the second field coil element 140 is mounted from its last layer on the periphery of the left-side core (circumferentially inside) of the two remaining pole cores 220 in Figure 20A circumferentially adjacent to the coil 130a.
Simultaneously with the mounting of the coil 140b on the left side core of the two remaining pole cores 22 0, the series connected profile coil 140a is mounted from its last layer on the periphery of the right-side core (circumferentially 1). outside) of the two remaining pole cores 220 in FIG. 20A. The coil end (leading end) Ta of the coil 140a and the coil end (leading end) Tb of the coil 130b are electrically connected to lead wires 170, respectively. The leads 170 are electrically connected to positive brushes 160, respectively. The coil end Ta of the coil 130a and the coil end Tb of the coil 140b extend outwardly (upwardly) in the axial direction of the cylinder head 215, and are electrically connected to a plate conductor 230.
In particular, when a continuous current is supplied to each of the coils 130a and 140b through the conductive plate 230, the direct current flowing through the coil 130a produces a magnetic flux in the axial direction of the coil 130a from the center of the coil. breech 215 towards its periphery. Similarly, the DC current flowing through the coil 130b produces a magnetic flux in the axial direction of the coil 130b toward the center of the cylinder head 215.
The DC current flowing through the coil 140b produces a magnetic flux in the axial direction of the coil 140b towards the center of the cylinder head 215. Similarly, the DC current flowing through the coil 140a produces a magnetic flux in the coil. axial direction of the coil 140a of the center of the cylinder head 215 towards its periphery.
In particular, when a reinforcement having a reinforcement winding wound around it is installed rotatably in the yoke 215 in front of each of the pole cores 220 with an air gap and a reinforcing current is When supplied to the winding, the reciprocating magnetic fluxes produced in the yoke 215 in its circumferential direction allow the armature to rotate about its axis of rotation.
As illustrated in FIGS. 18 to 20, the coil 140a of the second field coil element 140 is formed by winding the connecting wire 100 in profile and mounting it on the periphery of the corresponding core 220, the starting end Ta being left for a terminal of the coil 140. This causes the starting end Ta of the second field coil element 140 to extend outwardly from a first portion of the first turn of the coil 140a in the direction orthogonal to its axial direction and parallel to the axial direction of the yoke 215. The beginning end Ta, which extends outwardly from the profile coil member 140 mounted on the periphery of the corresponding core 220, an influence on the number of layers (turns) of the coil 140a corresponding to the number of turns thereof at its different parts.
In particular, since the beginning end Ta, which extends outwardly from the reel 140a, is arranged to intersect the connecting portion 120 between the reels 140a and 140b and a portion of the layers of the reel 140a. the number of layers of the crossing portion XA of the beginning end Ta of the reel 140a is one greater than that of the layers of another part of the reel 140a.
For example, it is assumed that the predetermined number of rotations of the coils 110a and 110b to produce each of the first and second field coil members 130 and 140 is set to two and one-half.
In this case, the number of layers of the crossing portion XA of the beginning end Ta of the reel 140a is 4 greater than that of the layers of another part of the reel 140a which is 3 (see FIG. in Figure 18B).
In particular, as illustrated in FIG. 18B, a space SO to mount the four layers of the coil 140a must be provided between the inner periphery 215a of the yoke 215 and the flange 221 of the corresponding pole core 220. However, because the number of layers of most parts of the coil 140a, except for the crossing portion XA, is 3, an interval of one layer appears in the SO space.
This may degrade a winding gap factor representing a measure of the use of SO space by the turns of the coil 140a, causing the physical size of the rotating electrical machine to increase.
The crossing portion XA of the coil 140a which has four layers (turns) causes the difference in the number of turns between the coils 140a and 140b. For example, a portion Y da of the reel 140b has two different layers, which differs from the crossing portion XA of the two-layer reel 140a.
Therefore, when a direct current is supplied to flow through the series-connected profile coils 140a and 140b, the difference in the number of turns between the coils 140a and 140b can unbalance the magnetic fluxes to be produced respectively by the coils 140a and 140b. 140b on the basis of direct current. This is because a magnetic flux to be produced by a coil is usually proportional to the number of turns of the coil.
The imbalance of the magnetic fluxes to be produced respectively by the coils 140a and 140b can cause variations in the output torque of the rotating electrical machine because the output torque is proportional to the intensity of the magnetic flux produced by each of the coils 140a. and 140b. The imbalance can also degrade the switching between the brushes and the armature winding 5d.
For the same reasons as for the second field coil element 14 0 mentioned above, an interval of one layer appears in a space intended to receive the four layers of the coil 130b disposed between the inner periphery 215a of the cylinder head 215 and the flange 221 of the corresponding pole core 220. This may degrade a winding gap factor representing a measure of the space utilization by the turns of the coil 130b.
In addition, the imbalance of the magnetic fluxes to be produced respectively by the coils 130a and 130b can cause variations in the output torque of the rotating electrical machine because the output torque is proportional to the intensity of the magnetic flux produced by each of the coils 130a and 130b. The imbalance can also degrade the switching between the brushes and the armature winding 5d. The beginning end extending outwardly from each of the first and second field coil members 130 and 140, which is wound in profile and mounted on the periphery of the corresponding core 220, influences the number of layers. (turns) of the coil 140a corresponding to the number of turns thereof at its different parts.
In particular, when the beginning end Tb of the first field coil element 130 and the corresponding blade 160 are offset in position in the circumferential direction of the yoke 215, the beginning end Tb of the first field coil element 13Q must be curved about an axis perpendicular to its long sides towards the corresponding broom 160. In other words, the beginning end Tb of the first field coil element 130 formed of the rectangular connecting wire 100 must be bent of profile to the corresponding broom 160.
Similarly, when the beginning end Ta of the second field coil element 140 and the corresponding broom 160 are offset in position in the circumferential direction of the yoke 215, the beginning end Ta of the second field coil element 140 consisting of the rectangular connecting wire 100 must be curved towards the corresponding broom 160.
However, the profile curvature of the beginning end of the rectangular connecting wire 100 requires a large load. Thus, when the leading end of the rectangular lead wire 100 already formed in a field coil member is curved in profile, the field coil member may be deformed. Further, as a rectangular connecting wire 100, an insulating film-coated connecting wire is used to form a field coil element, the profile curvature of the beginning end of the insulating film-coated connecting wire can be used to form a field coil element. causing the insulating film of the insulating film-coated connecting wire to fall.
The deformation of at least one of the field coil elements 130 and 140 can make it difficult to mount the connected field field coils of at least one of the field coil elements 130 and 140 on the field coils. the peripheries of the corresponding cores 220.
For these reasons, even though the leading end of at least one of the field coil elements 130 and 140 and the corresponding brush 160 are offset in position in the circumferential direction of the yoke 215, an electrical connection between 1 the beginning end and the corresponding broom 160 can be established using an electrical connection member without using the profile curvature. However, this can increase the number of parts for the rotating electrical machine, which results in an increase in its cost.
Further, the outwardly extending end end from each of the first and second field coil members 130 and 140, which is wound in profile and mounted on the periphery of the corresponding core 220, has an influence on the corresponding conductive wire among the conducting wires 170 connected to a corresponding brush of the brushes 160.
In particular, the rectangular connecting wire 100 has a substantially rectangular shape in its lateral cross-section orthogonal to its longitudinal direction and has a thickness substantially smaller than the width of its long sides 100a. With the configuration of the wire 100, the section module of the wire 100 is proportional to the square of its thickness and its width.
For this reason, each of the profile coils has a low stiffness vis-à-vis a force to be applied in the direction of the thickness thereof orthogonal to the long sides 100a, while it has a high rigidity screws to a force applied in the direction of its orthogonal width to the short sides.
When the set of field coils 200 described above is applied to a starter motor, as an example of rotating electrical machines, to be installed in a vehicle among various types of vehicles, a significant value of acceleration of Engine vibration installed in a vehicle among the various types of vehicles is applied to the engine of the starter motor.
For this reason, when the high vibration acceleration value of the motor is applied to the starter motor, the large amount of vibration acceleration is transferred to the field coil array 200. At this time, the coil ends Ta and Tb of the first and second field coil members 130 and 140 of the field coil assembly 200 are electrically connected to the lead wires 170 electrically connected to the brushes 160, respectively. For this reason, the large value of vibration acceleration is transferred to the coil ends Ta and Tb of the first and second field coil elements 130 and 140.
Since each of the coil ends Ta and Tb of the first and second field coil members 130 and 140 has a low rigidity to a force applied in the thickness direction thereof as As described above, the large amount of vibration acceleration can be transferred to the leads 170 through the corresponding coil ends Ta and Tb. This can damage the lead wires 170.
In addition, to increase the output torque of a starter motor in which such a profile coil has been installed as much as that of another starter motor in which a standard flat type coil has been installed while the size Physical profile coil is maintained in the state, the ratio of the width to the thickness of the profile coil should increase.
This further reduces the stiffness of the profile coil with respect to a force applied in the direction of its thickness, which may contribute to the deterioration of the lead wires 170 due to the high value of the vibration acceleration of the coil. engine.
Furthermore, in some uses of such profile coils, it is required to allow their number of turns to be adjustable. However, specific means for adjusting the number of turns of such profile coils is not disclosed in the US patent publication and / or the unexamined Japanese patent publications cited above.
Accordingly, it is an object of at least one aspect of the present invention to solve the above-described problems caused by at least one end of a profile coil element of a rotating electrical machine. extends outwardly therefrom. This profile coil element comprises a one-piece rectangular connecting wire wound in profile in at least one field coil.
Furthermore, it is an object of at least one other aspect of the present invention to adjust the number of turns of a profile coil element, this profile element comprises a rectangular one-piece wire bonded wire. in at least one pair of field coils connected in series.
According to one aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and first and second pole cores mounted on the circumferential surface. Each of the first and second pole cores has an outer periphery.
The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite large sides and a thickness therebetween, substantially less than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a first profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the first pole core. The field coil element comprises a second profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the second pole core. The field coil element comprises a connecting portion providing a connection between the first profile coil and the second profile coil in series. One of the first and second profile coils has a first coil end extending therefrom for crossing the connecting portion at a crossing portion thereof. The crossing portion between the first coil end and the connecting portion is designed not to overlap with the plurality of turns of one of the first and second profile coils.
According to another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and a pole core mounted on the circumferential surface. The pole core has an outer periphery. The outer periphery has at least one rounded corner. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the pole core. The profile coil has a first coil end. The first coil end of the profile coil extends from a start point on the at least one rounded corner of the pole core in a direction parallel to a tangential direction of the starting point of the first rounded corner. The direction in which the first coil end of the profile coil extends is inclined with respect to an axial direction of the yoke.
According to another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and first and second pole cores mounted on the circumferential surface. Each of the first and second pole cores has an outer periphery. The outer periphery has at least a first rounded corner. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a first profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially layered coils of the first profile coil is wound around the outer periphery of the first pole core. The first profile coil has a first end and the other coil end. The first coil end of the first profile coil extends from a start point on the at least first rounded corner of the first pole core in a direction parallel to a tangential direction of the starting point of the first rounded corner. The direction in which the first coil end of the first profile coil extends is inclined with respect to an axial direction of the cylinder head. The field coil element comprises a second profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially layered turns of the second profile coil is wound around the outer periphery of the second pole core. The second profile coil has a first end and the other end this coil. The first coil end of the second profile coil extends from a start point on the at least first rounded corner of the second pole core in a direction parallel to a tangential direction of the start point of the first rounded corner. . The direction in which the first coil end of the second profile coil extends is inclined with respect to the axial direction of the yoke, the other coil end of the second profile coil being electrically connected to the other end. coil of the first profile coil in series.
According to yet another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and a pole core mounted on the circumferential surface, the pole core having an outer periphery. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire, the rectangular connecting wire having a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil comprises a profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the pole core. The profile coil has a first coil end to be electrically connected to a conductor wire of a wiper for providing electrical contact with the armature. The first coil end of the profile coil extends therefrom. The field coil comprises a reinforcement formed on one of the long sides of the first coil end of the profile coil and acting to reinforce rigidity with respect to a force to be applied in the direction of the coil. thickness of the first coil end.
According to still another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and a pole core mounted on the circumferential surface, the pole core having an outer periphery. The rotating electrical machine comprises an electrically insulating coil having an annular peripheral portion mounted on the outer periphery of the pole core. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the annular peripheral portion of the electrically insulating coil. The profile coil has a first coil end to be electrically connected to a conductor wire of a wiper for providing electrical contact with the armature. The first coil end of the profile coil extends therefrom. The field coil comprises a fastener member integrally provided in the electrically insulating coil and configured to attach the first coil end of the profile coil.
According to still another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and first and second pole cores mounted on the circumferential surface. Each of the first and second pole cores has an outer periphery. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a first profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the first pole core. The field coil element comprises a second profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the second pole core. The field coil element comprises a connecting portion continuing between a first turn of the plurality of coaxially layered turns of the first profile coil and a first turn of the plurality of coaxially layered turns. of the second profile coil. A position of the connecting portion in a circumferential direction of the yoke is determined as a function of at least one turn of the number of turns coaxially disposed in layers of the first profile coil and the number of turns arranged in layers of coaxial region of the first profile coil.
According to still another aspect of the present invention, there is provided a rotating electrical machine for rotating a frame on the basis of a magnetic field. The rotating electrical machine comprises a yoke having a circumferential surface and first and second pole cores mounted on the circumferential surface. Each of the first and second pole cores has an outer periphery. The rotating electrical machine includes a field coil element operative to produce a magnetic field when energized. The field coil element is composed of a rectangular connecting wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The rectangular connecting wire is wound in profile in the field coil element. The field coil element comprises a first profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the first pole core. The field coil element comprises a second profile coil composed of a plurality of coaxially arranged coils. The plurality of coaxially arranged coils is wound around the outer periphery of the second pole core. The field coil element comprises a connecting portion disposed in an axial direction of the yoke so as to continue between a first turn of the plurality of coaxially arranged coaxial turns of the first profile coil and a first turn. of the plurality of turns coaxially arranged in layers of the second profile coil. A length of the connecting portion in the axial direction of the yoke is determined as a function of at least one turn of the number of turns coaxially arranged in layers of the first profile coil and the number of turns arranged in layers of coaxial way of the second profile coil.
According to yet another aspect of the present invention, there is provided a method of manufacturing a field coil element to be mounted on a circumferential surface of a cylinder head. The method includes providing a rectangular binder wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The method comprises the profile winding of the rectangular connecting wire from both a first end and the other end thereof to form: a first profile coil composed of a plurality of turns arranged in a coaxially layers on the first end of the rectangular connecting wire, a second profile coil consisting of a plurality of turns coaxially disposed on the other end of the rectangular connecting wire, and a connecting portion disposed on the remaining portion of the rectangular connecting wire between the first and second profile coils, one of the first and second profile coils having a first coil end extending therefrom for crossing the connecting portion at the of a crossing part thereof. The method comprises disposing the crossing portion between the first coil end and the connecting portion so that the crossing portion does not overlap with the plurality of coaxially layered turns of the first one of the first and second profile coils.
According to yet another aspect of the present invention, there is provided a method of manufacturing a field coil element having a profile coil to be mounted on a pole core mounted on a circumferential surface of a cylinder head. The pole core has an outer periphery. The outer periphery has at least one rounded corner. The method comprises providing a rectangular connecting wire, the rectangular connecting wire having a pair of opposite long sides and a thickness therebetween substantially less than a width of the long sides. The method includes providing a coil reinforcement. The coil reinforcement has an outer periphery of identical shape to the outer periphery of the pole core. The method comprises placing a small surface of a first end of the rectangular connecting wire in contact with the at least one rounded corner of the outer periphery of the coil reinforcement so that: one end of the first end of the Rectangular connecting wire is left thereon, and a predetermined angle is formed between a longitudinal direction of the rectangular connecting wire and a portion of the outer periphery of the coil armature opposite to the rectangular wire. The method comprises the profile winding of the rectangular connecting wire from its first end around the outer periphery of the coil reinforcement while a state of the first small surface of the first end of the rectangular connecting wire, which is in contact with the at least one rounded corner of the outer periphery of the coil reinforcement, is maintained to thereby form the profile coil composed of a plurality of coaxially arranged coils. The end of the rectangular connecting wire serves as the coil end of the profile coil. This method includes mounting the profile coil on the outer periphery of the pole core of the yoke so that the coil end of the profile coil extends from a start point on the at least first rounded corner of the pole core in a direction parallel to a tangential direction of the start point of the at least one rounded corner. The direction in which the coil end of the profile coil extends is inclined with respect to an axial direction of the yoke at the predetermined angle.
According to yet another aspect of the present invention, there is provided a method of manufacturing a field coil element having first and second profile coils to be respectively mounted on first and second pole cores mounted on a surface. circumference of a breech. Each of the first and second pole cores has an outer periphery. The outer periphery has at least one rounded corner. The method includes providing a rectangular binder wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The method includes providing first and second coils, the first coil reinforcement having an outer periphery of identical shape to the outer periphery of the first pole core. The second coil armature has an outer periphery of identical shape to the outer periphery of the second pole core. The method comprises placing a first small surface of a first end of the rectangular connecting wire in contact with the at least one rounded corner of the outer periphery of the first coil frame and a first small surface of the other end. rectangular connecting wire in contact with the at least one rounded corner of the outer periphery of the second coil frame so that: one end of the first end of the rectangular connecting wire is left thereon, a first predetermined angle formed between a longitudinal direction of the rectangular connecting wire and a portion of the outer periphery of the first coil reinforcement opposite the rectangular connecting wire, one end of the other end of the rectangular connecting wire is left thereon, a second predetermined angle is formed between a longitudinal direction of the rectangular connecting wire and a part of the outer periphery of the second coil reinforcement opposite to the rectangular connecting wire. The method comprises the profile winding of the rectangular connecting wire from the first end and the other end thereof around the outer peripheries of the first and second coils while a state of the first small surface of the first end of the rectangular connecting wire which is in contact with the at least first rounded corner of the outer periphery of the first coil reinforcement and that of the first small surface of the other end of the rectangular connecting wire which is in contact with the at least first rounded corner of the outer periphery of the second coil reinforcement are maintained to thereby form the first and second profile coils each composed of a plurality of coaxially arranged coils. The end of the first end of the rectangular connecting wire serves as the first coil end of the first profile coil. The end of the other end of the rectangular connecting wire serves as the second coil end of the second profile coil. The method comprises mounting the first profile coil on the outer periphery of the first pole core of the yoke so that the first coil end of the first profile coil extends from a start point on the at least first rounded corner of the first pole core in a direction parallel to a tangent direction ie; the beginning point of the at least one rounded corner, the direction in which the first coil end of the first profile coil is inclined by relative to an axial direction of the cylinder head at the first predetermined angle. The method includes mounting the second profile coil on the outer periphery of the second pole core of the yoke so that the second coil end of the second profile coil extends from a start point on the at least first rounded corner of the second pole core in a direction parallel to a tangential direction of the start point of the at least one rounded corner, the direction in which the second coil end of the second profile coil extends inclined with respect to a axial direction of the cylinder head at the second predetermined angle.
According to yet another aspect of the present invention, there is provided a method of manufacturing a field coil element to be mounted on a circumferential surface of a breech. The method includes providing a rectangular binder wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The method comprises the profile winding of the rectangular connecting wire from both a first end and the other end thereof to form: a first profile coil composed of a plurality of turns disposed in coaxially layers on the first end of the rectangular connecting wire, a second profile coil consisting of a plurality of turns coaxially disposed on the other end of the rectangular connecting wire, and a connecting portion continuing to between one of the plurality of coaxially coaxially arranged coils of the first profile coil and one of the plurality of coaxially layered coils of the second profile coil. The method comprises adjusting a circumferential position of the connecting portion as a function of at least one turn of the number of turns coaxially arranged in layers of the first profile coil and the number of turns arranged in layers of coaxial way of the first profile coil.
According to still another aspect of the present invention, there is provided a method of manufacturing a field coil element to be mounted on a circumferential surface of a cylinder head. The method includes providing a rectangular binder wire. The rectangular connecting wire has a pair of opposite long sides and a thickness between them substantially smaller than a width of the long sides. The method comprises the profile winding of the rectangular connecting wire from both a first end and the other end thereof to form: a first profile coil composed of a plurality of turns disposed in coaxially layers on the first end of the rectangular connecting wire, a second profile coil consisting of a plurality of turns coaxially disposed on the other end of the rectangular connecting wire, and a connecting portion continuing to between one of the plurality of coaxially coaxially arranged coils of the first profile coil and one of the plurality of coaxially layered coils of the second profile coil. The method comprises adjusting a length of the connecting portion in the axial direction of the yoke according to at least one turn of the number of coaxially layered turns of the first profile coil and the number of coils. of coaxially arranged coils of the first profile coil.
BRIEF DESCRIPTION OF THE DRAWINGS Further objects and aspects of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings, in which:
Figure 1 is an axial plan view of a starter motor according to a first embodiment of the present invention.
FIG. 2Ά is a circumferential developed view partially in cross-section of the inner periphery of a yoke of a yoke assembly of a set of field coils of the starter motor in a circumferential direction thereof in accordance with the first embodiment of realization.
Fig. 2B is a cross-sectional view of the field coil assembly taken along line A-A of Fig. 2A.
Figure 3 is a perspective view schematically illustrating the field coil assembly illustrated in Figure 2 except for the breech assembly.
Figs. 4A-4F are process graphs schematically illustrating a procedure for manufacturing a first field coil element of the field coil assembly illustrated in Figs. 1-3.
Figs. 5A-5F are process graphs illustrating in a simplified manner a procedure for manufacturing a second field coil element of the field coil assembly illustrated in Figs. 1 to 3.
Fig. 6 is a circumferential developed view partially in cross-section of a portion of the inner periphery of a yoke of a set of field coils according to a second embodiment of the present invention.
Fig. 7A is a view schematically illustrating a way of side-winding a rectangular connecting wire according to the first embodiment.
Fig. 7B is a view schematically illustrating one way of side-winding the rectangular connecting wire according to the second embodiment.
Figs. 8Ά to 8C are views substantially illustrating a method of pressing a second field coil element inwardly before the second field coil element is squeezed to form a curved shape which may be disposed along the the inner periphery of a cylinder head according to the second embodiment.
Fig. 9A is a circumferential developed view partially in cross section of the inner periphery of a yoke of a yoke assembly of a set of field coils of a starter motor in a circumferential direction thereof in accordance with a third embodiment of the present invention.
Fig. 9B is a cross-sectional view of the set of field coils taken along line B-B of Fig. 9A.
FIGS. 10A to 10G are process graphs illustrating in a simplified manner a procedure for manufacturing a second field coil element of the field coil assembly shown in FIG. 9A.
Figs. 11A to 11G are process graphs illustrating in a simplified manner a procedure for manufacturing a second field coil element according to a modification of the third embodiment.
FIG. 12A is a circumferential developed view partially in cross-section of the inner periphery of a yoke of a yoke assembly of a set of field coils of a starter motor in a circumferential direction in accordance with FIG. a fourth embodiment of the present invention.
Fig. 12B is a cross-sectional view of the set of field coils taken along line C-C of Fig. 12A.
Fig. 12C is an enlarged cross-sectional view of the field coil assembly taken along line D-D of Fig. 12A.
Figs. 13A to 13F are process graphs schematically illustrating a procedure for manufacturing a second field coil element of the field coil assembly shown in Fig. 12A.
Fig. 14A is a circumferential developed view partially in cross-section of a portion of the inner periphery of a yoke of a set of field coils according to a fifth embodiment of the present invention.
Fig. 14B is a view of a portion of the field coil assembly as seen from arrow E of Fig. 14A.
Figure ISA is a circumferential developed view partially in cross-section of a portion of the inner periphery of a yoke of a set of field coils according to a sixth embodiment of the present invention.
Fig. 15B is an axially cross-sectional view of a portion of the field coil assembly shown in Fig. ISA.
Fig. 16A is a circumferential developed view partially in cross-section of a portion of the inner periphery of a yoke of a set of field coils according to a seventh embodiment of the present invention.
Figure 1B is a cross-sectional view of the field coil assembly taken along line F-F of Figure 16A.
Fig. 16C is a view schematically illustrating the number of turns of a coil of a first field coil element electrically connected to a conductive plate shown in Fig. 16A.
Fig. 16D is a view schematically illustrating the number of turns of a coil of a first field coil element electrically connected to a conductive plate shown in Fig. 20.
Fig. 17A is a circumferential developed view partially in cross-section of a portion of the inner periphery of a yoke of a set of field coils according to a modification of the seventh embodiment.
Fig. 17B is a cross-sectional view of the set of field coils taken along line G-G of Fig. 17A.
Fig. 17C is a view schematically illustrating the number of turns of a coil of a first field coil element electrically connected to a lead wire shown in Fig. 17A.
Fig. 17D is a view schematically illustrating the number of turns of a coil of the first field coil element electrically connected to a conductive plate shown in Fig. 17A.
Figs. 187k to 18F are process graphs illustrating in a simplified manner a procedure for manufacturing a first conventional field coil element of a set of field coils.
Figures 197k to 19F are process graphs illustrating in a simplified manner a procedure for manufacturing a second conventional field coil element of the field coil assembly, and
Figure 20A. is a circumferential developed view partially in cross section of the inner periphery of a yoke of a breech assembly of a conventional field coil assembly of a starter motor in a circumferential direction thereof, and
Fig. 20B is a cross-sectional view of the field coil assembly taken along line H-H of Fig. 20A.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings. In the embodiments, like references designate like parts in multiple views.
FIRST EMBODIMENT
Referring to Figure 1, there is illustrated a starter motor 1 for starting a motor of a vehicle. This starter motor 1 is an example of a rotary electric machine according to a first embodiment of the present invention.
The starter motor 1 consists of a set of field coils 3 serving as a stator thereof, and a frame (rotor) 5. The frame 5 consists of a rotation shaft 5a and a core annular armature 5b mounted on the rotational shaft 5a to surround it. The armature core 5b has a plurality of groove-shaped slots 5c formed on an outer periphery of the armature core 5b so as to be circumferentially arranged, for example, at regular intervals. The armature 5 is also constituted by a frame winding 5d mounted in the notches 5c of the core 5b to be wound around them. The field coil assembly 3 is comprised of a breech assembly 11. The breech assembly 11 consists of a breech 13 which is substantially ring-shaped and has four pole cores 15. The breech 13 serves as the magnetic circuit for the field coil assembly 3.
As illustrated in Figures 1 and 2A, the yoke 13 is made of an annularly wound metal sheet, such as for example ferromagnetic materials.
In particular, the yoke 13 has an annular outer periphery, an annular inner periphery 13a opposite thereto, a first edge (upper edge in Fig. 2A) 13b, and a second edge 13c (lower edge in Fig. 2A) opposite to this one.
The four pole cores 15 are mounted on the inner periphery 13a of the yoke 13 at substantially regular intervals. Note that FIG. 2A is a developed view of the inner side of the yoke 13 of the field coil assembly 3 in a circumferential direction thereof.
Each of the four pole cores 15 is configured to protrude radially from the inner periphery 13a of the yoke 13 so as to have a substantially round rectangular cylindrical shape. In particular, each of the four pole cores 15 has a pair of rounded upper corners 15a, a pair of rounded lower corners 15b opposite one another, a pair of opposite longitudinal sides 15c, and a pair of opposite side sides 15d,
Each of the four pole cores 15 is formed at its projecting end of a flange 17 for supporting a field coil element described hereinafter. The field coil assembly 3 is comprised of a pair of first and second field coil members 21 and 23.
The first field coil element 21 is installed in any two of the four pole cores circumferentially adjacent to each other, and the second field coil element 23 is installed in the remaining two of the four cores. Pole cores 15.
As illustrated in FIGS. 2 and 3, the first field coil element 21 consists of a pair of serially connected profile coils 21a and 21b. In a similar manner, the second field coil element 23 consists of a pair of series connected profile coils 23a and 23b.
Next, a procedure for manufacturing the first field coil element 21 will be described hereinafter with reference to FIGS. 4Ά to 4F.
As illustrated in FIG. 4A, to fabricate the first field coil element 21, a continuous rectangular wire 25 having a predetermined length suitable for manufacturing the first field coil element 21 and a pair of first and second coils 27a and 27b are prepared.
Each of the first and second coils 27a and 27b has a round rectangular cylindrical shape substantially equivalent to the shape of each of the cores 15. The rectangular connecting wire 25 has a thickness substantially less than the width of its long sides 25a.
A small side 25b of a first end portion of the connecting wire 25 is contacted on a first longitudinal side of the periphery of a first end of the first coil armature 27a so as to leave a predetermined elongated end Ea of it. The first end portion of the bonding wire 25 is clamped by the clamping mechanism of the first coil armature 25a so that the state of contact between the first short side 25b of the bonding wire 25 and the first longitudinal side of the the first coil reinforcement 27a is maintained.
Similarly, the other small side 25c of the other end of the connecting wire 25 is brought into contact on a first longitudinal side of the periphery of the first end of the second coil reinforcement 27b so as to leave an elongated end predetermined Eb of it. The other end portion of the connecting wire 25 is clamped by a clamping mechanism of the second coil reinforcement 27b so that the state of contact between the other small side 25c of the connecting wire 25 and the first side longitudinal of the second coil reinforcement 27b is maintained.
Then, as illustrated in FIG. 4B, the first and second reel armatures 27a and 27b are respectively rotated on their central axes 180 degrees (one half-turn) in a predetermined direction, for example the opposite direction of the needles of a shown in FIG. 4B, as they approach each other because the connecting wire 25 is under tension.
This allows the small sides 25b and 25c of the first end portion and the other end portion of the connecting wire 25 to be wound in profile on the peripheries of the first and second coil frames 27a and 27b, respectively.
Then, as illustrated in FIG. 4C, the first and second coil armatures 27a and 27b are respectively rotated on their central axes at 90 degrees in the counterclockwise direction so that each of the debug ends Ea and Eb connecting wire 25 crosses one of the long sides 25a of the connecting wire 25. This forms a first turn (first layer) wound in profile around a corresponding periphery among the peripheries of the first and second reel frames 27a and 27b .
After that, as illustrated in FIG. 4D, the first and second reel armatures 27a and 27b are respectively rotated on their central axes at 90 degrees in the counterclockwise direction. In other words, the first and second coils 27a and 27b are turned counterclockwise on their central axes 360 degrees (one turn) from their original states illustrated on Figure 4A.
After that, a predetermined number, for example, one-and-a-half turns of the coils 27a and 27b in the counterclockwise direction is executed.
In particular, the execution of the substantially complete two-and-a-half turns of the bobbins 27a and 27b allows the jumper 25 to be wound at their small sides 25b and 25c (at their edges) on the outer peripheries of the bobbins 27a and 27b. first and second coils 27a and 27b from the first and the other ends of the connecting wire 25 towards the center thereof, respectively.
This forms three successive turns (partially two turns) of the connecting wire 25 wound in profile around the first and second coil plates 27a and 27b respectively. The three successive loops leave the remaining center of the connecting wire 25 by moving away in the same axial directions as those of the first and second reel plates 27a and 27b (see Figures 4D and 4E).
After completion of substantially two and one-half turns of the coil armatures 27a and 27b, a pair of spaced coil elements connected to each other by a connecting portion 29 is generated (see FIG. 4E). .
Next, the center of the short side 25c of the connecting portion 29 is brought into focus on a curved surface of a first end of a folding template 31 having a predetermined curvature along it.
After that, the pair of coil elements is bent at the contact portion of the connecting portion 29 with respect to the curved surface of the first end of the folding jig 31, so that: the spaced coil elements getting closer. the beginning ends Ea and Eb of the connecting wire 25 are substantially parallel to one another, and one end of the last turn of the coil element corresponding to the second coil reinforcement 27b and the connecting portion 33 continuing thereafter are pressed away from the turns of the coil element corresponding to the second coil reinforcement 27b (see Fig. 4F). Removal of the pair of coil elements from the first and second coil plates 27a and 27b provides the second field coil element 33 consisting of the pair of series connected series coils 23a and 23b (see FIG. 4F).
After that, the first field coil element 21 is pressed to form a curved shape so that the connecting portion 29 protrudes outwardly with respect to the coils 21a and 21b (see FIG. 3). This curved shape can be arranged along the inner periphery 13a of the yoke 13.
After that, the curved coil member 21 is disposed along the inner periphery 13a of the yoke 13. The coils 21a and 21b are mounted on the peripheries of any two of the four circumferentially adjacent pole cores 15. to the other, so that: the first turn (first layer) of each of the coils 21a and 21b is arranged the innermost in the axial direction thereof, and the last turn (last layer) of each coils 21a and 21b are arranged outermost in the axial direction thereof.
Similarly, a procedure for manufacturing the second field coil element 23 will be described hereinafter with reference to Figs. 5A-5F.
As illustrated in FIG. 5A, to produce the second field coil element 23, the identical bonding wire 25 and the first and second coils 27a and 27b are prepared.
Each of the first and second coils 27a and 27b has a round rectangular cylindrical shape substantially equivalent to the shape of each of the cores 15. The rectangular connecting wire 25 has a thickness substantially less than the width of its long sides 25a.
In comparison with the manufacturing procedure of the first field coil element 21, the other small side 25c of a first end portion of the connecting wire 25 is brought into contact on a first longitudinal side of the periphery of a first end of the first coil reinforcement 27a so as to leave a predetermined elongate end Ea thereof. The other small side 25c of the first end portion of the connecting wire 25 is clamped by the clamping mechanism of the first coil reinforcement 27a.
Similarly, the first small side 25b of the other end of the connecting wire 25 is brought into contact on a first longitudinal side of the periphery of a first end of the second coil reinforcement 27b so as to leave an elongated end predetermined Eb of it. The first side 25b of the other end portion of the connecting wire 25 is clamped by the clamping mechanism of the second coil reinforcement 27b.
In this manner, as well as the first field coil element 21, substantially two and one-half turns of the coil arches 27a and 27b are made in a clockwise direction (see FIGS. 5B-5E).
In particular, the execution of substantially two and one-half turns of the coil reinforcements 27a and 27b allows the bonding wire 25 to be wound at their small sides 25c and 25b (at their edges) on the outer peripheries of the first and second coils 27a and 27b from the first end and the other end of the bond wire 25 toward the center thereof, respectively.
This forms three successive turns (partially two turns) of the connecting wire 25 wound in profile around the first and second coils 27a and 27b, respectively. The three successive loops start from the remaining center of the connecting wire 25 by moving away from it in the same axial directions of the first and second coils 27a and 27b (refer to Figures 5D and 5E).
After completion of the substantially two and one-half turns of the bobbins 27a and 27b, a pair of spaced bobbin members connected to each other by a link portion 33 is generated (see Fig. 5E). .
Then, like the first field coil element 21, the center of the short side 25c of the connecting portion 33 is brought into contact with the curved surface of the first end of the folding jig 31.
After that, the pair of coil elements is bent at the contact portion of the connecting portion 33 with respect to the curved surface of the first end of the folding jig 31, so that: the separate coil elements approaching, the leading ends Ea and Eb of the connecting wire 25 are substantially parallel to each other, and one end of the last turn of the coil element corresponding to the first coil reinforcement 27a and the portion link 33 continuing thereafter are pressed away from the turns of the coil element corresponding to the first coil armature 27a (see Figure 5F). Removal of the pair of coil elements from the first and second coil armatures 27a and 27b provides the second field coil element 23 consisting of the pair of serially connected profile coils 23a and 23b (see FIG. 5F).
After that, the second field coil element 23 is pressed to form a curved shape so that the connecting portion 33 protrudes outwardly with respect to the coils 23a and 23b (see FIG. 3); this curved shape can be arranged along the inner periphery 13a of the yoke 13.
After that, the curved coil member 23 is arranged along the inner periphery 13a of the yoke 13. The coil 23b is mounted on the periphery of one of the two remaining pole cores circumferentially adjacent to the poles 15 on which the coil 21 is mounted so that: the first turn (first layer) is arranged most inward in the axial direction thereof, and the last turn (last layer) is arranged the outermost in the axial direction of it.
Similarly, the coil 23a is mounted on the periphery of the other core among the two remaining pole cores 15, so that: the first turn (first layer) is arranged the innermost in the axial direction of this, and the last turn (last layer) is arranged the outermost in the axial direction thereof.
As illustrated in FIGS. 2 and 3, the start end Eb of the series connected profile coil 21b serves as a coil end thereof. The coil end Eb extends to the first edge 13b of the yoke 13 from a portion of the first turn of the coil 21b in a direction orthogonal to its axial direction and parallel to the axial direction of the yoke 13 so as to protrude outwardly from the first edge 13b of the yoke 13.
Similarly, the start end Ea of the series connected profile coil 23a serves as a coil end thereof. The coil end Ea extends towards the first edge 13b of the yoke 13 from a first portion of the first turn of the coil 23a in a direction orthogonal to the axial direction thereof and parallel to the direction the bobbin end 13b of the bobbin 21b and the coil end Ea of the bobbin 23a are electrically connected to lead wires 41, respectively. The conductive wires 41 are electrically connected to positive brushes 43, respectively. Positive brushes 43 and negative brushes (not shown) provide electrical contact with the armature winding 5d. The coil end Ea of the coil 21a and the coil end Eb of the coil 23b extend outwardly parallel to the axial direction of the cylinder head 13, and are electrically connected to a first end of a coil. conductive plate 45.
The first end of the conductive plate 45 is supported by a rubber grommet 47 fixedly disposed between the yoke 13 and a first end frame of the starter motor 1. The other end of the conductive plate 25 is electrically connected to a fixed contact 51 of an electromagnetic switch 51, and the other fixed switch 51b is electrically connected to a battery 53. The electromagnetic switch Sla has a movable contact 51c mechanically connected to an actuator for the starter motor 1. The actuator acts to move the movable contact 51c to allow electrical connection between the two fixed contacts Sla and 51b.
In particular, as illustrated in FIGS. 1 and 2, the pair of series-connected field coils 21a and 21b and the pair of field-connected field coils 23a and 23b are connected in parallel to the battery 53 via the electromagnetic switch 51.
When a start trigger signal is inputted to the actuator so that the movable contact 51c is moved to allow electrical connection between the two fixed contacts Sla and 51b, a direct current is supplied from the battery 53 parallel to the coils 21a and 23b through the conductive plate 45.
The direct current flowing through the coil 21a produces a magnetic flux in the direction of the coil 21a from the center of the yoke 13 towards its periphery. Similarly, the direct current flowing through the coil 21b produces a magnetic flux in the axial direction of the coil 21b towards the center of the yoke 13.
The direct current flowing through the coil 23b produces a magnetic flux in the axial direction of the coil 23b towards the center of the cylinder head 13. Similarly, the direct current flowing through the coil 23a produces a magnetic flux in the coil. axial direction of the coil 23a of the center of the cylinder head 13 towards its periphery.
On the other hand, the direct current is supplied as the armature current to the armature winding 5d of the armature 5 via the coils 21b and 23a, the conductive wires 41, and the brushes 43. Therefore, the reciprocating magnetic fluxes produced in the yoke 13 in the circumferential direction thereof allow the armature 5 to rotate at the same time as the rotation shaft 5a.
In the starter motor illustrated in FIGS. 1 to 3, and in accordance with the first embodiment, during the process of manufacturing the second field coil element 23, the end of the last turn of the coil 23a and the Connection portion 33 continuing therethrough is pressed away from the turns of the coil 23a (see Fig. 5F). This allows the connecting portion 33 not to overlap with the turns of the coil 23a and extends substantially parallel to the first edge 13b of the yoke 13.
In particular, as illustrated in FIGS. 2 and 3, the connecting portion 29 continuing from the outermost turn of the coil 21a extends upwardly from a rounded upper corner portion 15a of the pole core. 15 corresponding to the coil 21a, and extends circumferentially above the turns of the coil 21b to continue toward the outermost turn of the coil 21b.
Therefore, as illustrated in FIG. 2A, a crossing portion X between the beginning end Ea extending outwardly from the spool 23 and the connecting portion 33 is arranged so as not to overlap with the turns of the coil 23a.
This non-overlapping arrangement of the crossing portion X allows the number of layers (turns) of a portion of the coil 23a to be substantially equal to that of another portion thereof.
In the first embodiment, since substantially two and one-half turns of the coil armatures 27a and 27b are executed to produce each of the first and second field coil elements 21 and 23, the number of layers of a portion XI of the coil 23a is 3, which is equal to the number of layers of another portion X2 thereof (see Figure 2B).
In particular, as illustrated in FIG. 2B, a space S1 intended to receive the three layers of the coil 23a must be provided between the inner periphery 13a of the yoke 13 and the collar 17 of the corresponding pole core 15.
Accordingly, in comparison with a case where a space 50 for receiving the four layers of the coil 140a is required in the field coil assembly 200 shown in Fig. 20A, the configuration of the coil assembly 3 increases a winding space factor representing a measurement of the use of the SI space by the turns of the coil 23a. This allows the physical size of the field coil assembly 3 to decrease compared to that of the field coil assembly 200 shown in Fig. 20A, thereby reducing the size of the starter motor 1.
In addition, the non-overlapping arrangement of the crossing portion X allows the number of layers of the coil 23a to be less than or equal to three. This allows the difference between the number of revolutions of a part Y of the reel 23b and the number of revolutions of any part of the reel 23a to be established to be at most 1. That is to say that the number of turns of the coil 23a is set to be substantially equal to the number of turns of the coil 23b. For this reason, when a direct current is supplied to flow through the series-connected profile coils 23a and 23b, it is possible to balance the magnetic flux to be produced respectively by the coils 23a and 23b on the basis of DC current.
For the same reasons as the second field coil element 23 mentioned above, the number of turns of the coil 21a is set to be substantially equal to the number of turns of the coil 21b. Thus, when a DC current is supplied to flow through the serially connected profile coils 21a and 21b, it is possible to balance the magnetic flux to be produced respectively by the coils 21a and 21b based on the DC current. The equilibrium of the magnetic fluxes to be produced respectively by the coils 21a, 21b, 23a, and 23b contributes to the reduction of the variations of the output torque of the starter motor 1 because the output torque is proportional to the intensity of the magnetic flux produced by each of the coils 21a, 21b, 23a and 23b. In addition, the balance also helps to prevent the switching between the brushes and the armature winding 5d is degraded.
Second embodiment
FIG. 6 is a circumferential developed view of a portion of the inner periphery 13a that includes two pole cores 15, a yoke 13 of a set of field coils 3a according to a second embodiment of the present invention. . Identical portions between field coil assemblies 3a and 3, to which identical references are assigned, are omitted or simplified with respect to the description.
The serially connected profile coils 23a1 and 23b1 of a second field coil element 23X of the field coil assembly 3a are respectively mounted on the two pole cores 15.
As illustrated in FIG. 6, the set of field coils 3a according to the second embodiment is designed, like the set of field coils 3, according to the first embodiment.
In particular, a connecting portion 33a is arranged not to overlap with the turns of the spool 23a so that a crossing portion X between the starting end Ea which extends outwardly from the spool 23al and the connecting portion 33a is arranged not to overlap with the turns of the coil 23al. Note that, in the second embodiment, the connecting portion 33a is configured to extend obliquely with respect to the first edge 13b of the yoke 13.
In the second embodiment, the field coil assembly 3a is wound in profile around the peripheries of the first and second coil armatures 27a and 27b in a manner different from that used for the field coil assembly 3 in accordance with the present invention. in the first embodiment.
Fig. 7A schematically illustrates how to roll up the rectangular lead wire 25 in accordance with the first embodiment. Figure 7B schematically illustrates how to roll up the rectangular connecting wire 25 in accordance with the second embodiment.
As illustrated in FIG. 7A, in the first embodiment, the connecting wire 25 is wound around the periphery of a first end of the first coil reinforcement 27a in the circumferential direction thereof towards the other end. of the first coil reinforcement 27a.
Conversely, as illustrated in FIG. 7B, in the second embodiment, the first end of the connecting wire 25 is wound around the periphery of a first end of the first reel armature 27a in an inclined direction. relative to the circumferential direction thereof to the other end of the connecting wire 25.
Similarly, the other end of the connecting wire 25 is wound around the periphery of a first end of the second coil arm 27b in a direction inclined with respect to the circumferential direction thereof towards the first end of the coil. binding wire 25.
In particular, removal of the pair of coil elements from the first and second coil plates 27a and 27b (see Fig. 5F) provides the second field coil element 23X consisting of the pair of connected profile coils. in series 23al and 23bl.
FIG. 8A substantially illustrates the second field coil element 23X seen on the arrow VIII of FIG. 6 before the second field coil element 23X is squeezed to form the curved shape allowing it to be arranged along the inner periphery 13a of the cylinder head 13.
As illustrated in FIGS. 7A and 8A, the number of layers of the coil 23al at the inclined side TS1 thereof appears to be 4. For this reason, when the second field coil element 23X is simply installed on the inner periphery 13a of the yoke 13 after being pressed to form the curved shape, a space S OA for receiving four layers of the second field coil element 23X must be provided between the inner periphery 13a of the yoke 13 and the collar Corresponding poles cores 15.
However, in the second embodiment, the crossing portion X between the starting end Ea, which extends outwardly from the coil 23a1, and the connecting portion 33a, is arranged not to overlap. with the turns of the coil 23al. The non-overlapping configuration of the cross-over portion X allows that: a portion C of the coil 23al, whose number of layers is 2 less than 3, is formed between the coil end Ea of the coil 23al and the coil portion 23a. link 33, and the number of layers of the remaining portions of the coil 23al is 3.
Therefore, in the second embodiment, at the same time as the second coil member 23X is pressed to form the curved shape, the first and second layers of the coil 23a1 are pressed inwardly at the portion C of the in order to be stepped inwards at this level. This allows the inclined side TS1 of the coil 23al to be substantially aligned with the coil end Ea thereof (see Fig. 8C).
Further, at the same time as the second reel member 23X is pressed to form the curved shape, the first and second layers of the reel 23b1 are pressed inward at its portion Y so as to be staggered towards the interior at this level. This allows an inclined side TS2 of the coil 23bl to be substantially aligned with the coil end Eb thereof (see Figure 8C).
Consequently, after the coils 23a1 and 23b1 are mounted from their outermost layers (last turns) on the two cores of corresponding poles 15, the number of turns of the coils 23a1 and 23b1, for example three turns , correspond substantially to each other around the cores of corresponding poles 15.
Consequently, as in the first embodiment, it is only necessary to allocate a space SIA to accommodate three layers of the coils 23a1 and 23b1 between the inner periphery 13a of the yoke 13 and the flanges 17 of the corresponding pole cores 15 This allows a winding gap factor, which represents a measure of the use of the SIA space by the turns of the coils 23a1 and 23b1, to increase. Increasing the winding gap factor of the field coil assembly 3a reduces the physical size of the field coil assembly 3a compared to that of the field coil assembly 200 shown in FIG. FIG. 20A, thus reducing the size of the starter motor 1.
In addition, as in the first embodiment, because the number of turns of the coil 23al is set to be substantially ecfal to the number of turns of the coil 23bl, it is possible to balance the magnetic flux to be produced respectively by the coils 23a1 and 23b1 based on the DC current flowing therethrough.
In addition, in the second embodiment, at the same time as the second coil member 23X is pressed to form the curved shape, the first and second layers of the coils 23a1 and 23b1 are pressed inwardly at their C parts. and Y so as to be stepped inward there, respectively. This can easily produce the second 23X coil element without additional processes.
For the same reasons as for the second field coil element 23X mentioned above, when the first field coil element 21 is of a configuration similar to the second field coil element 23X, the effects described above obtained by the second field coil element 23X can also be obtained.
Third embodiment
Fig. 9A is a circumferential expanded view of the inner periphery 13a of a yoke 13 of a set of field coils 3a according to a third embodiment of the present invention. Descriptions of like parts between sets of field coils 3b and 3, which are assigned identical references, are omitted or simplified. The field coil assembly 3b is comprised of a pair of first and second field coil elements 61 and 63.
The first field coil element 61 is installed in any two of the four pole cores circumferentially adjacent to each other, and the second field coil element 63 is installed in the two remaining cores of the four pole cores. 15.
As in the first and second embodiments, as illustrated in FIG. 9A, the first field coil element 61 consists of a pair of profile coils 61a and 61b connected to each other in series through one another. of a connecting portion 65. Similarly, the second field coil element 63 consists of a pair of profile coils 63a and 63b connected to one another in series through a portion of link 67.
Each of the first and second field coil elements 61 and 63 is produced by circumferentially winding the rectangular lead 25 with a suitable predetermined length to produce a corresponding element of the first and second field coil members 61 and 63 of a corresponding manner among the ways described below.
The rectangular connecting wire 25 has opposite large sides 25a and small opposite sides 25b and 25c, and has a thickness between the short sides 25b and 25c substantially less than the width of its long sides 25a.
Each of the profile coils 61a and 61b has a number of turns, and each of the profile coils 63a and 63b also has a number of turns.
The coils 61a and 61b are mounted on the peripheries of any two of the four pole cores circumferentially adjacent to each other so that the turns of each of the coils 61a and 61b are arranged to be layered from each other. the inner periphery 13a of the yoke 13 to the corresponding flange 17 in the axial direction thereof.
Similarly, the coils 63a and 63b are mounted on the peripheries of the two remaining pole cores 15 so that: the coil 53b is mounted on the periphery of one of the two remaining pole cores circumferentially adjacent to the pole on which the coil 61a is mounted, and the turns of each of the coils 63a and 63b are arranged to be arranged in coaxial layers from the inner periphery 13a of the yoke 13 to the corresponding collar 17.
An end portion EPa of the innermost turn of the coil 61a is wrapped around a first rounded lower corner 15b of the corresponding pole core 15 circumferentially adjacent the coil 63b and extends from the along a longitudinal side 15c thereof in the axial direction of the yoke 13.
A coil end Ea of the end portion EPa of the innermost turn of the coil 61a extends outwardly toward the first edge 13b of the yoke 13 from a start point on a rounded upper corner 15a of the corresponding pole core 15 so that the short side 25b thereof is inclined at an angle of Θ1 with respect to the longitudinal side 15c parallel to a tangential direction at the starting point of the first upper corner rounded 15a.
Similarly, an end portion EPb of the innermost turn of the coil 53b is wound around a first rounded lower corner 15b of the corresponding pole core 15 circumferentially adjacent the coil 61a and extends from there along a longitudinal side 15c thereof in the axial direction of the yoke 13.
A coil end Eb of the end portion EPb of the innermost turn of the coil 63b extends outwardly toward the first edge 13b of the yoke 13 from a start point on a first rounded upper corner 15a of the corresponding pole core 15 so that the short side 25b thereof is inclined at the angle of Θ1 with respect to the longitudinal side 15c parallel to a tangential direction at the starting point of the first rounded upper corner 15a.
As in the first embodiment, the coil end Ea of the coil 61a and the coil end Eb of the coil 63b are electrically connected to a first end of the conductive plate 45 supported by the rubber grommet 47. .
An end portion EPb of the innermost turn of the coil 61b is wound around a first rounded lower corner 15b of the corresponding pole core 15 circumferentially adjacent the coil 61a and extends outwardly. to the first edge 13b of the yoke 13 from a start point on the first rounded lower corner 15b so that the short side 25c thereof is inclined at an angle of Θ2 with respect to a longitudinal side 15c of the corresponding pole 15 continuing from the first rounded lower corner 15b parallel to the axial direction of the yoke 13.
Similarly, an end portion EPa of the innermost turn of the coil 63a is wrapped around a first rounded lower corner 15b of the corresponding pole core 15 circumferentially adjacent to the coil 63b and s'. extends outwardly toward the first edge 13b of the yoke 13 from a start point on the first rounded lower corner 15b so that the short side 25c thereof is inclined at the angle of Θ2 relative to to a longitudinal side 15c of the corresponding pole 15 continuing from the first rounded lower corner 15b parallel to the axial direction of the yoke 13.
A coil end Eb of the end portion EPb of the coil 61b and a coil end Ea of the end portion EPa of the coil 63a are electrically connected to the lead wires 41, respectively. The conductive wires 41 are electrically connected to the positive brushes 43, respectively.
Next, a procedure for manufacturing the second field coil element 63 will be described hereinafter with reference to FIGS. 10A to 10G.
As illustrated in FIG. 10A, the short side 25c of a first end portion of the connecting wire 25 is brought into contact on a first rounded corner of the periphery of a first end of the first coil reinforcement 27a so that that: a predetermined elongate end Ea is left thereon, and a direction of a first longitudinal side of the first coil reinforcement 27a in contact on the short side 25c is inclined at an angle of β1 relative to the short side 25c . The angle of β1 is substantially equivalent to the angle of Θ2.
The first end portion of the bonding wire 25 is tightened by the clamping mechanism of the first coil reinforcement 27a so that the state of contact between the first end of the bonding wire 25 and the first rounded corner of the first coil reinforcement 27a is maintained.
Similarly, the small side 25b of the other end of the bonding wire 25 is contacted on the first rounded corner of the periphery of the first end of the second coil frame 27b so that: a predetermined elongate end Eb be left thereon, and a direction of a first longitudinal side of the second coil reinforcement 27b, in contact on the short side 25b, is inclined at an angle of α relative to the short side 25b. The angle of α1 is substantially equivalent to the angle of Θ1. The other end portion of the connecting wire 25 is clamped by the clamping mechanism of the second coil reinforcement 27b so that the state of contact between the other end of the connecting wire 25 and the first rounded corner of the the second coil reinforcement 27 is maintained.
Then, as illustrated in FIG. 10B, the second coil reinforcement 27b is rotated on its central axis at the angle of α1 clockwise in FIG. Since the state of contact between the other end of the bonding wire 25 and the first rounded corner of the second coil reinforcement 27b is maintained, the end Eb of the bonding wire 25 is inclined at the angle of el relative to the longitudinal direction of the remaining connecting wire 25.
On the other hand, as illustrated in FIG. 10B, the first coil reinforcement 27a is rotated on its central axis at a clockwise angle of (180-β1) degrees in FIG. Since the state of contact between the first end of the connecting wire 25 and the first rounded corner of the first coil reinforcement 27a is maintained, a direction of the short side 25c of the end Ea of the connecting wire 25 is inclined. the angle of β1 with respect to the first longitudinal side of the first coil reinforcement 27a.
After that, as well as the second field coil element 23 according to the first embodiment, a rotation of the coil armature 27b clockwise by 180 degrees (half-turn) is executed. This allows the small side 25b of the other end portion of the connecting wire 25 to be wound in profile on the periphery of the second coil reinforcement 27b (see Figures 10B to 10D).
In this way, after the U-turn, two turns of the second coil reinforcement 27b in a clockwise direction are executed. This allows the small side 25b of the other end portion of the connecting wire 25 to be wound in profile on the periphery of the second coil reinforcement 27b. This forms three successive turns (partially two turns) of the connecting wire 25 wound in profile around the second coil reinforcement 27b. The three successive loops start from the connecting wire 25 by moving away in the same axial directions as the second coil reinforcement 27b (see Figures lOD and 10E).
On the other hand, as the second field coil element 23 according to the first embodiment, a rotation of the coil armature 27b in the clockwise direction by 180 degrees (one-half turn) is performed. This allows the small side 25c of the other end portion of the connecting wire 25 to be wound in profile on the periphery of the first coil reinforcement 27a (see Figures 10C to 10D);
In this manner, for example, substantially two turns and a half total of the first coil reinforcement 27a clockwise from the original state illustrated in Fig. 10A are executed. This allows the small side 25c of the first end portion of the connecting wire 25 to be wound in profile on the periphery of the first coil reinforcement 27a. This forms three successive turns (partially two turns) of the wire 25 wound in profile around the first coil armature 27a. The three successive loops start from the connecting wire 25 by moving away in the same axial directions of the first coil reinforcement 27a (see Figures lOD and 10E).
In particular, after completion of substantially two and one-half turns of the bobbins 27a and 27b, a pair of spaced bobbin members connected to each other by a connecting portion 67 is generated (refer to FIG. Figure 10E).
Then, a first end of the short side 25c of the connecting portion 67 near the coil reinforcement 27b is brought into contact on the curved surface of the first end of the folding template 31.
After that, the pair of coil elements is bent at the contact portion of the connecting portion 67 with respect to the curved surface of the first end of the folding template 31 so that: the spaced coil elements are the Ea and Eb ends of the connecting wire 25 are substantially parallel to one another, and one end of the last turn of the coil element corresponding to the. first coil reinforcement 27a and the connecting portion 33 which continues therethrough are pressed away from the turns of the bobbin member corresponding to the first bobbin reinforcement 27a (see Fig. 10F). Removal of the pair of coil elements from the first and second coil plates 27a and 27b provides the second field coil element 63 consisting of the pair of series connected series coils 63a and 63b (see FIG. 10F).
As illustrated in FIG. 1G, the series-connected profile coils 63a and 63b are formed at the same side of the connecting portion 67, which is similar to the series-connected profile coils 21 and 23 in accordance with the first embodiment of FIG. production. It should be noted that in FIG. 1G, the arrows AR indicate the directions of the magnetic fluxes produced by the coils 63a and 63b when a DC current is supplied from the coil end Eb of the coil 63b to the coil end Ea. of the coil 63a.
After that, the second field coil element 63 is pressed to form a curved shape so that the connecting portion 67 protrudes outwardly with respect to the coils 63a and 63b. This curved shape can be arranged along the inner periphery 13a of the yoke 13.
After that, the curved coil member 63 is arranged along the inner periphery 13a of the yoke 13. The coils 63a and 63b are mounted on the peripheries of any two of the four pole cores circumferentially adjacent to each other. Other such that: the first turn (first layer) of each of the coils 63a and 63b is arranged most inwardly in the axial direction thereof, and the last turn (last layer) of each of the coils 63a. and 63b is arranged outermost in the axial direction thereof.
Since a manufacturing procedure of the first field coil element 61 is substantially similar to a combination of the manufacturing procedure of the second field coil element 63 and the manufacturing procedure of the first field coil element 21 according to in the first embodiment, their descriptions are omitted.
In particular, as illustrated in FIG. 10H, the short side 25b of the first end of the connecting wire 25 is brought into contact on a first rounded corner of the periphery of a first end of the first coil reinforcement 27a so that the predetermined elongated end Ea is left thereon, and a first longitudinal side of the first coil reinforcement 27a which is not in contact on the short side 25b is inclined at the angle of al relative to the small side 25b. The angle of α1 is substantially equivalent to the angle of Θ1.
The first end portion of the bonding wire 25 is clamped by the clamping mechanism of the first coil reinforcement 27a so that the contact state between the other end of the bonding wire 25 and the first rounded corner of the first coil reinforcement 27a is maintained.
Similarly, the short side 25c of the other end portion of the connecting wire 25 is contacted on a first rounded corner of the periphery of a first end of the second coil frame 27b so that: predetermined elongated end Eb is left thereon, and a first longitudinal side of the second coil reinforcement 27b, in contact on the short side 25c, is inclined at the angle of β1 with respect to the short side 25c. The angle of βΐ is substantially equivalent to the angle of Θ2. The other end portion of the connecting wire 25 is clamped by the clamping mechanism of the second coil reinforcement 27b so that the state of contact between the other end of the connecting wire 25 and the first rounded corner of the the second coil reinforcement 27b is maintained.
After that, the same manufacturing procedure as that of the first coil element 21 is performed (see FIGS. 4A-4F).
Accordingly, the curved coil member 61 is arranged along the inner periphery 13a of the yoke 13. The coil 61a is mounted on the periphery of one of the two remaining pole cores circumferentially adjacent to the pole 15 on which the coil 63b is mounted so that: the first turn (first layer) is arranged most inward in the axial direction thereof, and the last turn (last layer) is arranged the outermost in the axial direction of these.
Similarly, the coil 63b is mounted on the periphery of the other one of the two remaining pole cores so that: the first turn (first layer) is arranged the innermost in the axial direction of those and the last turn (last layer) is arranged the outermost in the axial direction thereof.
In the starter motor 1 illustrated in FIGS. 9 and 10 according to the third embodiment, a change of the angle of φ1 allows the direction in which the coil end of each of the coils 61a and 63b extends to be adjusted. Similarly, a variation of the angle of Θ 2 allows the direction in which the coil end of each of the coils 63a and 61b extends to be adjusted.
Thus, even if the coil end of each of the coils 61b and 63a and the corresponding brush 43 are offset in position in the circumferential direction of the yoke 13, an electrical connection between the coil end of each of the coils 61b and 63a and the corresponding broom 43 can be easily established without the use of electrical connection elements. This increases the design flexibility of the starter motor 1, and reduces the number of parts for the starter motor 1 to thereby prevent the increase of its cost.
Further, in the embodiment, the angle of Θ1 or Θ2 of the coil end of each of the first and second series connected coil elements 61 and 62 is previously defined with respect to the corresponding forward wire 25. that the corresponding rectangular connecting wire 25 is formed in the corresponding coil element.
Thus, winding the corresponding rectangular connecting wire around each of the first and second coil armatures 27a and 27b allows either the pair of coils 61a and 61b to be the coils 63a and 63b and their coil ends Ea and Eb having respectively the inclined angles of Θ1 and Θ2 with respect to a direction parallel to the axial direction of the yoke 13 are formed integrally.
This can eliminate the need to bend the ends of coils Ea and Eb either coils 61a and 61b, or coils 63a and 63b after the winding process. This makes it possible to manufacture: both the matched coils 61a and 61b, and the matched coils 63a and 63b to be mounted on the corresponding pole cores 15 with high dimensional accuracy, and the ends of coils which respectively extend from the coils. matched coils 61a and 61b and matched coils 63a and 63b with high dimensional accuracy.
Further, even though, as a rectangular connecting wire 25, an insulating film-coated connecting wire is used to form at least one of the field coil elements 61 and 63, the elimination of the need to bend the ends of coils Ea and Eb are coils 61a and 61b or coils 63a and 63b after the winding process can prevent the insulating film of the insulating film-coated binder wire from falling.
As described above, in the third embodiment, a first pair of field-connected field coils can be produced from a single rectangular lead wire 25. Thus, in comparison with a case of making a coil from a single rectangular lead wire, a higher dimensional accuracy to produce a pair of field connected field coils is required.
To meet the requirement, in the third embodiment, the angle of Θ1 or Θ2 of the coil end of each of the first and second series connected coil elements 61 and 63 is set in advance for the corresponding connecting wire 25 before the corresponding rectangular connecting wire 25 is formed into the corresponding coil element. In addition, each of the first and second coil members 61 and 63 is configured to be firmly mounted on the corresponding pole cores 15. This prevents any of the first and second coil members 61 and 63 from being set up. disorder.
Further, as in the first embodiment, a crossing portion X between the coil end Ea which extends outwardly from the spool 63a and the connecting portion 67 is arranged not to overlap with the turns of the coil 63a.
This non-overlapping arrangement of the crossover portion X allows the number of layers (turns) of a portion of the coil 23a to be substantially equal to that of another portion thereof (see FIG. 9B).
Consequently, the non-overlapping arrangement of the crossing portion X makes it possible to obtain the effects obtained in the first embodiment described above.
In the third embodiment, as described above, the series-connected profile coils 63a and 63b are produced to be formed at the same side of the connecting portion 67, but the present invention is not limited to manufacturing process and coil configuration.
In particular, as a modification of the third embodiment, a procedure for manufacturing a second field coil element 63X will be described hereinafter with reference to Figs. 11A to 11G.
As illustrated in FIG. 11A, the short side 25b of a first end portion of the connecting wire 25 is brought into contact on a first rounded corner of the periphery of a first end of the first coil reinforcement 27a so that that: a predetermined elongated end Ea is left thereon, and a direction of a first longitudinal side of the first bobbin reinforcement; 27a in contact on the short side 25b, is inclined at a corner angle with respect to the short side 25b. the angle of pia is substantially equivalent to the angle of Θ2.
The first end portion of the bonding wire 25 is tightened by the clamping mechanism of the first coil reinforcement 27a so that the state of contact between the first end of the bonding wire 25 and the first rounded corner of the first coil reinforcement 27a is maintained.
Similarly, the short side 25b of the other end portion of the connecting wire 25 is also brought into contact on the first rounded corner of the periphery of the first end of the second coil reinforcement 27b so that predetermined elongated end Eb is left thereon, and a direction of a first longitudinal side of the second coil reinforcement 27b, in contact on the short side 25b, is inclined at a pia angle with respect to the short side 25b to an angle ala equivalent to the angle βΐ3 with respect to the short side 25b. The angle ala is substantially equivalent to the angle Θ1.
Next, a revolution of the first coil reinforcement 27a at the anti-clockwise angle is performed. After that, a half turn of the first coil armature 27a counterclockwise (Figure IIB) and after that a turn of the latter counterclockwise 90 degrees. (Fig. IIC) are executed so that the starting end Ea of the connecting wire 25 crosses one of the long sides 25a of the connecting wire 25.
This forms a first turn (first layer) wound in profile around the periphery of the first coil reinforcement 27a.
Similarly, a revolution of the second coil reinforcement 27b at the clockwise angle of ala is performed. After that, a half turn of the second coil armature 27b in a clockwise direction (Fig. 11B) and thereafter turn it clockwise 90 degrees (Fig. IIC) are executed so that the beginning end Eb of the connecting wire 25 crosses the other of the long sides 25a of the connecting wire 25.
This forms a first turn (first layer) wound in profile around the periphery of the second coil reinforcement 27b.
After that, one and a half turns of the first coil armature 27a counterclockwise and one and a half turns of the second coil armature 27b clockwise are respectively performed.
As a result, three successive turns (partially two turns) of the connecting wire 25 wound in profile around the periphery of each of the first and second coil frames 27a and 27b are formed.
The three successive loops of the first coil reinforcement 27a start from the remaining center of the connecting wire 25 in the opposite axial directions of the first and second reel plates 27a and 27b (see Figure IIE).
In particular, after completion of the one-and-a-half turn of the coil armatures 27a and 27b, a pair of spaced coil elements connected to one another with a connecting portion 67 is generated (see FIG. ).
Then, the center of the connecting portion 67 is brought into contact on the curved surface of the first end of the folding jig 31.
After that, the pair of coil elements is bent at the contact portion of the connecting portion 67 with respect to the curved surface of the first end of the folding template 31 so that: the spaced coil elements are close together, and the beginning ends Ea and Sb of the connecting wire 25 are substantially symmetrical with respect to the connecting portion 67 (see Figure 11F). Removal of the pair of coil elements from the first and second coil armatures 27a and 27b provides the second field coil element 63X consisting of the pair of 63Xa and 63Xb series connected coil coils (refer to FIG. Figure 11F).
As illustrated in FIGS. 11F and 11G, the 63Xa and 63Xb series-connected profile coils are arranged to be symmetrical with respect to their connecting portion 67. The arrows AR indicate the directions of the magnetic fluxes produced by the coils 63Xa and 63Xb when DC current is supplied from the coil end Eb of the coil 63Xb to the coil end Ea of the coil 63Xa.
In another modification of the third embodiment, each of the first and second field coil elements 61 and 63 consists of a pair of serially connected profile coils produced with the use of the single wire 25, but the present invention is not limited to the structure.
In particular, each of the first and second field coil members 61 and 63 may consist of a profile coil produced with the use of the single lead 25.
In the third embodiment, the coil end of each of the coils 61a and 61b of the first field coil element 61 has a predetermined inclined angle with respect to a first longitudinal side of a corresponding one of the pole cores 15 Similarly, the coil end of each of the coils 63a and 63b of the second field coil element 63 has a predetermined inclined angle with respect to a first longitudinal side of a corresponding one of the pole cores 15.
However, in the present invention, the coil end of only one of the coils 61a and 61b of the first field coil element 61 may have a predetermined inclined angle with respect to a first longitudinal side of a corresponding one of the cores similarly, the coil end of only one of the coils 63a and 63b of the second field coil element 63 may have a predetermined inclined angle with respect to a first longitudinal side of a corresponding one of the Pole cores 15.
Fourth embodiment
Fig. 12A is a circumferential expanded view of the inner periphery 13a of a yoke 13 of a set of field coils 3c according to a fourth embodiment of the present invention. The identical parts between the sets of field coils 3c and 3b, to which identical references are assigned, are omitted or simplified in the description.
Each member of a pair of first and second field coil members 51Y and 63Y of the field coil assembly 3c has a substantially identical configuration to the pair of first and second field coil members 61 and 63 of the Field coil assembly 3b with the exception of the following: (1) The coil end Ea of the coil 61a of the first field coil element 61Y does not have an angle inclined with respect to a first longitudinal side 15c a corresponding kernel parm; the pole cores 15. (2) The coil end Eb of the coil 63b of the second field coil element 61Y does not have an inclined angle with respect to a first longitudinal side 15c of a corresponding one of the cores of poles 15, (3) The number of turns of each of the coils 61a, 61b, 63a and 63b is set to be substantially three and a half, so that four successive turns (partly three turns) of each of the coils 61a, 61b , 63a and 63b are formed (see Figure 12B). (4) The coil end Ea, Eb of each of the coils 63a and 61b extending towards the first edge 13b of the yoke 13 while being inclined at the angle Θ2 with respect to a longitudinal side 15c of the corresponding pole 15 is formed at a first major side 25al, a rib type reinforcing member 70 protruding. The reinforcing member 70 is designed to increase the stiffness with respect to a force to be applied in the thickness direction of the coil end of each of the coils 63a and 61b orthogonal to its long sides. 25a.
For example, as illustrated in Fig. 12C, the coil end Ea of the coil 63a is concavely repelled in its longitudinal direction from the other long side 25a2, which faces a connecting portion 67a between the coils 63a. and 63b, to the first large side 25al. This allows the first major side 25a of the coil end Ea to be formed, the reinforcing member 70 having a predetermined length in the longitudinal direction of the coil end Ea.
It should be noted that in the fourth embodiment, the coil end Ea of the coil 63a is concavely repelled along its length from the other long side 25a2 to a first large side 25al so as to leave a TI end on it to which the corresponding conductor wire 41 is electrically connected.
In other words, while the flat tip TI is left, the reinforcing member 70 is formed on the first long side 25a1 of the coil end Ea close to the flat end TI.
Similarly, the coil end Eb of the spool 61b is concavely repelled in the lengthwise direction from the other large side 25a2, which faces a connecting portion 65a between the spools 61a and 51b, the first big side 25al. This allows the first major side 25a of the coil end Eb to be formed with the reinforcing member 70 which has a predetermined length in the direction of the length of the coil end Eb.
A manufacturing procedure for each of the first and second field coil elements 51Y and 63Y is substantially identical to that of a corresponding one of the first and second field coil elements 61 and 63.
For example, to fabricate the second field coil element 63Y, as shown in FIG. 13A, the reinforcing member 70 is formed on the first major side 25a of the coil end Ea, the tip TI being left on so as to have a predetermined length in the direction of the length of the coil end Ea.
Next, the short side 25c of a first end portion of the bonding wire 25 is contacted on a first rounded corner of the periphery of a first end of the first coil reinforcement 27a so that: the end A coil Ea is left, and a direction of a first longitudinal side of the first coil reinforcement 27a which is in contact on the short side 25c is inclined by the angle β1 with respect to the short side 25c. The angle β1 is substantially equivalent to the angle of Θ2.
The first end portion of the bonding wire 25 is tightened, for example, at the reinforcing member which exceeds 70 by the clamping mechanism of the first coil reinforcement 27a so that the state of contact between the first end of the connecting wire 25 and the first rounded corner of the first coil reinforcement 27a is maintained.
Conversely, the short side 25b of the other end of the bonding wire 25 is brought into contact on a first longitudinal side of the periphery of a first end of the second coil reinforcement 27b so as to leave the predetermined elongate end Eb of it. The small side 25b of the other end portion of the connecting wire 25 is clamped by the clamping mechanism of the second coil reinforcement 27b.
After that, substantially three and one-half turns of the clockwise coils 27a and 27b are executed (FIGS. 13B-13D corresponding to FIGS. 5B-5E at the first end-side and FIGS. 3E at the other end side).
After practically three and one-half turns of the bobbins 27a and 27b, a pair of spaced bobbin members connected to each other by a link portion 67 is generated (refer to FIG. 13E).
Then, the center of the connecting portion 67a is brought into contact on the curved surface of the first end of the folding jig 31.
After that, the pair of coil elements is bent at the contact portion of the connecting portion 57a with respect to the curved surface of the first end of the folding jig 31 so that: the spaced coil elements are the early ends Ea and Eb of the connecting wire 25 are substantially opposed to each other, and one end of the last turn of the coil member corresponding to the first coil reinforcement 27a and the portion of link 33 continuing therethrough are pressed away from the turns of the coil member corresponding to the first coil reinforcement 27a (see Fig. 13F). Removal of the pair of coil elements from the first and second coil armatures 27a and 27b provides the second field coil element 63Y consisting of the pair of serially connected profile coils 63a and 63b (see FIG. 13F).
As described above, in the fourth embodiment, the coil ends Ea, Eb of each of the coils 63a and 63b extending towards the first edge 13b of the yoke 13 to be electrically connected to the corresponding wire among the conductive wires. 41, are formed at a first large side 25a, the reinforcing member 70 protruding.
For example, because the reinforcing member 70 is configured to protrude outwardly from the first major side 25a of the coil end, it is possible to increase the sectional module of the coil end to -vis a force to apply in the direction of its thickness. This allows the coil end of each of the coils 63a and 61b to have high rigidity. This prevents the coil end of each of the coils 63a and 61b from vibrating significantly even if a large amount of vibration acceleration is transferred to its coil end, thereby preventing the conductive wire 41 connected to the end. coil of each of the coils 63a and 61b does not vibrate significantly.
This makes it possible to improve the resistance to the vibration of the coil end of each of the coils 63a and 61b and to prevent the conductive wires 41 from deteriorating for example in this brittle, because of the transfer of the acceleration of the vibration at their ends of coils.
Further, in the fourth embodiment, the reinforcing member 70 is formed on the first major side 25a1 of the first end portion of the bonding wire 25 before the bonding wire 25 is wound around the periphery of the coil reinforcement 27a.
Accordingly, as described above, it is possible for the clamping mechanism to easily grip the first end portion of the bonding wire 25 through the use of the reinforcing member 70. This may prevent a portion the connecting wire 25 to be clamped is not deformed, which allows the tension applied to the connecting wire 25 to be kept substantially constant. This makes it possible to prevent each of the first and second coil elements 61Y and 63Y from being dismounted. The reinforcing member 70 is formed of the first major side 25a of the coil end of each of the coils 63a and 61b extending outwardly from their turns. For this reason, when the bonding wire 25 is wrapped around the periphery of each of the first and second coil frames 27a and 27b, the bonding wire 25 can be prevented from interfering with the previously formed reinforcing member 70. For the same reason, the turns of each of the coils 61a, 61b, 63a, and 63b can be prevented from being disassembled.
Fifth embodiment
Fig. 14A is a circumferential expanded view of a portion of the inner periphery 13a of a yoke 13 of a set of 3d field coils according to a fifth embodiment of the present invention. The identical parts between the sets of field coils 3d and 3c, which are assigned identical references, are omitted or simplified in the description.
A second field coil element 63Y of the 3d field coil assembly has a configuration substantially identical to that of the second field coil element 63Y of the field coil assembly 3c except for the following point: A instead of the reinforcing member 70, the coil end Ea of the spool 63a extending to the first edge 13b of the yoke 13 and protruding is formed with a folded portion 73 to provide a double thickness thereto. this. At the folded portion 73, the corresponding lead wire 41 is electrically connected.
In particular, as illustrated in Fig. 14B, a beginning H of the coil end Ea of the coil 63a is folded around a line on the other long side 25a2 along its width so that the other large 25a2 of the beginning H comes abutting that of the coil end Ea adjacent to its beginning H. This allows that the folded pairing 73 having the double thickness of the coil end Ea is formed. The corresponding conducting wire 41 is electrically connected to the first large side 25al of the beginning H of the coil end Ea.
As described above, in the fifth embodiment, the folded portion 73 of the coil end Ea of the coil 63a has its increased thickness between the long sides 25a1 and 25a2. Increasing the thickness of the folded portion 73 increases the sectional modulus of the folded portion 73 of the coil end Ea with respect to a force to be applied in the direction of its thickness.
This allows the folded coil end 73 of the coil 63a to have high rigidity. This prevents the folded spooled end 73 of the spool 63a from vibrating significantly even if a large amount of vibration acceleration is transferred to the spool end Ea, thereby preventing the conductive thread 41 connected to the spool. folded spool end 63 of spool 63a does not vibrate significantly.
This makes it possible to improve the vibration resistance of the folded coil end 73 of the coil 63a and to prevent the corresponding conductive wire 41 from deteriorating, for example by breaking, due to the transfer of the acceleration of vibration at its coil end Ea.
Further, in the fifth embodiment, increasing the thickness of the folded coil end 73 of the coil 63a can prevent a portion of the bonding wire 25 to be squeezed from deforming, thereby allowing the voltage applied to the wire 25 is kept substantially constant.
This prevents the second coil element from being disassembled. The coil end Eb of the spool 61b extending towards the first edge 13b of the yoke 13 and protruding may be formed with a folded portion 73 to provide a double thickness, thereby obtaining the effects described herein. -above.
Sixth embodiment
Figure ISA is a circumferential developed view of a portion of the inner periphery 13a of a yoke 13 of a third field coil assembly according to a sixth embodiment of the present invention. The identical parts between the sets of field coils 3e and 3c, to which identical references are assigned, are omitted or simplified in the description.
In the sixth embodiment, no reinforcing member is formed on the coil end Ea of the coil 63a which extends to and extends beyond the first edge 13b of the yoke 13.
In the sixth embodiment, the field coil assembly 3e has a specific structure as compared to the field coil assembly 3c.
In particular, the field coil assembly 3e is provided with a plastic coil 81 arranged between the second coil element 63 and the cylinder head assembly 11 and acting to support the second coil element 63 while at the same time insulation of the bolt assembly 11.
The coil 81 is composed of a coil support member Sla, a pair of rectangular cylindrical portions 81b, a first flange 81c, a second flange 81d, and a connecting portion 81e.
As illustrated in FIG. 15B, the paired rectangular cylindrical portions 81b are respectively mounted on the peripheries of the pole cores 15 for the coils 63a and 63b of the second coil element 63.
The first flange 81c extends outwardly from a first rectangular cylindrical edge of each of the cylindrical portions 81b in a circumferential direction of the yoke 13. This first rectangular cylindrical edge abuts on the inner periphery 13a of the yoke 13.
The second flange 81d extends outwardly from the other rectangular cylindrical edge of each of the cylindrical portions 8Ib in a circumferential direction of the yoke 13. This other rectangular cylindrical edge abuts on the flange 17 of the corresponding pole core 15 .
A first circumferential end of one of the circumferentially adjacent second flanges 81d and a first circumferential end of the second circumferentially adjacent flanges 81d, which are opposed to each other, are connected to each other, this connecting portion serving as link part 81e. The coil support member 81a is mounted on an inner surface of the connecting portion 81e opposite the inner periphery 13a of the yoke 13.
As illustrated in FIG. 15B, the coil support member Sla consists of a pair of hooks K1 and K2 designed to clamp the coil end Ea of the coil 63a which extends to the first edge 13b of the yoke 13. .
The coils 53a and 63b are completely covered with an adhesive element 83, such as powdered resins or thermoset liquid adhesive, and after that they are fixedly mounted on the outer peripheries of the corresponding cylindrical portions 8 Ib of the insulating coil 81 through the adhesive element 83, respectively.
With the structure of the field coil assembly 3e according to the sixth embodiment, the coil end Ea of the coil 63a is fixedly supported by the coil support member 81a and fixedly supported on the coil. insulating coil 81 through the adhesive element 83.
This makes it possible to improve the vibration resistance of the coil end Ea of the coil 63a, and to prevent the corresponding conductive wire 41 from deteriorating, for example by breaking, due to the transfer of the acceleration of the coil. vibration at its coil end Ea.
Further, the entire second field coil element 63 is covered with the adhesive element 83 to be attached to the insulating coil 81. This can reduce induced micro-vibrations between axially adjacent layers of each of the coils 63a and 53b. , making it possible to improve the second field coil element 63 (the set of field coils 3e).
The plastic insulating coil 81 may be arranged between the first coil element 61 and the cylinder head assembly 11 and act to support the first coil element 63 while isolating it from the breech assembly 11, and the entire the second field coil element 63 may be covered with the adhesive element 83 to be attached to the insulating coil 81. This may achieve the same effects as those in accordance with the sixth embodiment described above.
In addition to the reinforcing member 70, the coil end Ea of the coil 63a which extends to and extends beyond the first edge 13b of the yoke 13 may be formed with the collapsed portion 73 to provide a double thickness of it.
Seventh embodiment
Fig. 16A is a circumferential expanded view of the inner periphery 13a of a yoke 13 of the field coil assembly 3f according to a seventh embodiment of the present invention. The description of the identical parts between the sets of field coils 3f and 3b, to which identical references are assigned, is omitted or simplified.
Each element of a pair of first and second field coil elements 61Z and 63Z of the field coil assembly 3f has a configuration substantially identical to that of the pair of first and second field coil elements 61 and 63 of Field coil assembly 3b except for the following: (1) The coil end Ea of the coil 61a of the first field coil element 61Z does not have an angle inclined with respect to a first longitudinal side 15c of a first corresponding one of the pole cores 15. (2) The coil end Eb of the coil 63b of the second field coil element 61Z does not have an inclined angle with respect to a first longitudinal side 15c of a corresponding one of the pole cores 15. (3) The coil end Ea of the end portion EPa of the innermost turn of the coil 63a extends outwardly toward the first edge 13b of the culas from a start point on a first rounded upper corner 15a of the corresponding pole core 15 so that its short side 25c is inclined at an angle Θ3 with respect to a tangential direction at the starting point of the first rounded upper corner 15a. (4) The coil end Eb of the end portion EPb of the innermost turn of the coil 61b extends outwardly toward the first edge 13b of the yoke 13 from a starting point on a first rounded upper corner 15a of the corresponding pole core 15 so that its short side 25c is inclined at the angle Θ3 with respect to a longitudinal direction at the starting point of the first rounded upper corner 15a. (5) The number of turns of each of the coils 61a, 61b, 63a and 63b is set to be substantially three and a half so that four successive turns (partly three turns) of each of the coils 61a, 61b, 63a and 63b are formed (see Figure 16B). (6) As shown in Fig. 16A, a connecting portion 91 continuing from the outermost turn of the coil 61a extends upwardly from a first rounded lower corner portion 15b, which is circumferentially adjacent at the coil 61b, of the pole core 15 corresponding to the coil 61a, and continues toward the outermost turn of the coil 61b at a first rounded upper corner portion 15a, which is circumferentially adjacent to the coil 61a, the pole core 15 corresponding to the coil 61b.
During a manufacturing procedure of the field coil assembly 3f, the arrangement of the link portion 91 can be performed in the folding process (refer to Fig. 16F).
As is clearly seen by comparison between FIG. 16C and FIG. 16D, the number of turns of the coil 61a is substantially less than half a revolution to that of the turns of the coil 130a shown in FIG. in Figures 16C and 16D, numerical characters which are indicated on the coils 61a and 130a represent the number of turns (turns) thereof.
In particular, as illustrated in FIG. 20, the connecting portion 120, which continues from the innermost turn of the coil 130a, extends circumferentially from a first rounded upper corner portion 15a, which is circumferentially adjacent to the coil 130b, of the pole core 15 corresponding to the coil 130a, and continues towards the outermost turn of the coil 130b at a first rounded upper corner portion 15a, which is circumferentially adjacent to the coil 130a, of the pole core 15 corresponding to the coil 130b.
Thus, as illustrated in FIGS. 16D and 20, the number of turns (layers) of the coil 130a along the two longitudinal sides 15c of the corresponding pole core 15 is defined as 4.
Conversely, as illustrated in FIGS. 16A and 16C, the number of turns (layers) of the coil 61a along a first longitudinal side 15c of the corresponding pole core 15 near the connecting portion 91 is defined as 3 1 less than that of turns (layers) of the coil 61a along its other longitudinal side 15c.
This allows the number of turns of the coil 61a to be less than that of the turns of the coil 130a by substantially one-half (0.5) revolution.
Like the connecting portion 91, the connecting portion 93 which continues from the outermost turn of the coil 63b extends upwardly from a first rounded lower corner portion 15b, which is circumferentially adjacent to the coil 63a, of the pole core 15 which corresponds to the coil 63b, and continues to the outermost turn of the coil 63a at a first rounded upper corner portion 15a, which is circumferentially adjacent the coil 63b, the pole core 15 corresponding to the coil 63a.
Therefore, for the same reasons as for the first field coil element 61Z, the configuration of the connecting portion 93 allows the number of turns of the coil 63b to be less than that of the turns of the coil 140b by substantially one-half ( 0.5) turn.
Since the set of field coils 3f consists of the first and second field coil elements 61Z and 63Z, it is possible to adjust the number of turns of the field coil assembly 3f into one. tower.
As a modification of the field coil assembly 3f, as illustrated in FIG. 17A, a connecting portion 91A continuing from the outermost coil of the coil 61a extends circumferentially from an intermediate portion. a first longitudinal side 15c, which is circumferentially adjacent to the coil 61b, of the pole core 15 corresponding to the coil 61a, and continues to the outermost turn of the coil 61b at the level of an intermediate portion of a first longitudinal side 15c, which is circumferentially adjacent to the coil 61a, of the pole core 15 corresponding to the coil 61b.
As is clearly seen by comparing FIG. 17C and FIG. 17D, the number of turns of the coil 61a is nearly a quarter of a turn shorter than the number of turns of the coil 61b. It should be noted that in FIGS. 17C and 17D, numerical characters indicated on the coils 61a and 61b represent their numbers of turns (turns).
As described above, in the seventh embodiment and its modifications, a variation of either the circumferential position or the axial direction of the connecting portion 91, 91A extending from the coils 61a and 61b allows that the number turns of either the profile coil 61a or the profile coil 61b is adjusted.
In other words, the variation of the axial length of the connecting portion 91, 91A arranged axially to continue between the coils 61a and 61b allows the number of turns of one or the other of the profile coil. 61a or the profile coil 61b is adjusted.
This makes it possible to adjust a magnetic flux to be produced in the axial direction of either the profile coil 61a or the profile coil 61b, thereby controlling the output torque of the motor 1 starter.
In the first to fifth embodiments and the seventh embodiment, an electrically insulating coil may be disposed between at least one of the first and second coil members and the breech assembly 11. In this case, the element Sla coil support device described in the sixth embodiment may be provided for clamping the coil end of at least a first coil of the at least one of the first and second coil elements.
In the first to seventh embodiments, the present invention is applied to starter motors for vehicles, but the present invention is not limited to applications. In particular, the present invention can be applied to other types of rotating electrical machines to excite a field coil to produce a magnetic flux therein.
Although it has been described what is now considered to be the embodiments and their modifications of the present invention, it will be understood that various modifications, which are not yet described, can be made thereto, and it is intended to to cover in the appended claims all modifications which are in the true spirit and scope of the invention.

权利要求:
Claims (21)
[1" id="c-fr-0001]
A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and a pole core mounted on the circumferential surface; the pole core having an outer periphery, the outer periphery having at least a first rounded corner, a field coil element (21) operative to produce a magnetic field when excited, the field coil element (21) ) being composed of a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the field coil element (21), the field coil element (21 ) comprising: a profile coil composed of a plurality of coaxially arranged coils, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the pole core, the profile coil having a first coil end (Ea, Eb), the first coil end (Ea, Eb) of the profile coil extending from a start point on the at least one rounded corner of the pole core in a direction parallel to the direction tangentially from the start point of the first rounded corner, the extension direction of the first coil end (Ea, Eb) of the profile coil being inclined with respect to an axial direction of the yoke (13).
[2" id="c-fr-0002]
2. A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and first and second pole cores mounted on the circumferential surface, each of the first and second pole cores having an outer periphery, the outer periphery having at least one first rounded corner, a field coil element (21) operative to produce a magnetic field when energized, a field coil element (21) being composed of a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the eleme field coil element (21), the field coil element (21) comprising: a first profile coil composed of a plurality of coaxially arranged coils, the plurality of coaxially layered coils of the first profile coil being wound around the outer periphery of the first pole core, the first profile coil having a first end and another coil end (Ea, Eb), the first coil end (Ea, Eb) of the first profile coil extending from a start point on the at least first rounded corner of the first pole core in a direction parallel to a tangential direction of the starting point of the first rounded corner, the direction of extension of the first coil end (Ea, Eb) of the first profile coil being inclined with respect to an axial direction of the cylinder head (13), and a second plurality of profile coil of coaxially arranged coils, the plurality of coaxially coaxially arranged coils of the second profile coil being wound around the outer periphery of the second pole core, the second profile coil having a first end and another coil end (Ea, Eb), the first coil end (Ea, Eb) of the second profile coil extending from a start point on the at least first rounded corner of the second pole core in a direction parallel to a tangential direction of the starting point of the first rounded corner, the direction of extension of the first coil end (Ea, Eb) of the second profile coil being inclined with respect to the axial direction of the yoke (13), the other coil end (Ea, Eb) of the second profile coil being electrically connected to the other coil end (Ea, Eb) of the first series profile coil.
[3" id="c-fr-0003]
3. A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and a pole core mounted on the circumferential surface; the pole core having an outer periphery, a field coil element (21) operative to produce a magnetic field when energized, the field coil element (21) being comiposed with a rectangular connecting wire ( 25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the field coil element (21), the field coil comprising: a profile coil composed of a plurality of arranged turns in layers coaxially, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the pole core, the profile coil having a first coil end (Ea, Eb) to be electrically connected to a wire conductor of a broom to provide electrical contact with the armature (5), the first coil end (Ea, Eb) of the profile coil extending therefrom, and a reinforcement formed on one of the long sides (25a) of the first coil end (Ea, Eb) of the profile coil and acting to reinforce the stiffness with respect to a force to be applied in the direction of the thickness of the first end of coil (Ea, Eb).
[4" id="c-fr-0004]
The rotary electric machine according to claim 3, wherein the reinforcement comprises a protruding element protruding from the first of the long sides (25a) of the first coil end (Ea, Eb) of the profile coil.
[5" id="c-fr-0005]
The rotary electrical machine according to claim 4, wherein the protruding element is formed by concavely pushing the first coil end (Ea, Eb) of the profile coil in a length direction thereof from the other of the long sides (25a) to the first of the long sides (25a) while one end of the first coil end (Ea, Eb) is left on, the conductive wire being electrically connected at the end of the first end of coil (Ea, Eb) of the profile coil.
[6" id="c-fr-0006]
The rotary electrical machine according to claim 4, wherein the reinforcement comprises a folded portion to impart a double thickness between the long sides (25a) of the first coil end (Ea, Eb) of the profile coil, the wire conductor being electrically connected to the folded portion.
[7" id="c-fr-0007]
The rotary electric machine according to claim 6, wherein the folded portion is formed by folding a beginning of the first coil end (Ea, Eb) of the profile coil around a line on the other long side along of its width, so that the other large side of the beginning abuts that of the coil end (Ea, Eb) adjacent to its beginning.
[8" id="c-fr-0008]
A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and a pole core mounted on the circumferential surface; the pole core having an outer periphery, an electrically insulating coil having an annular peripheral portion mounted on the outer periphery of the pole core, a field coil element (21) operative to produce a magnetic field when energized, field coil element (21) being composed of a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness therebetween being substantially less than one width of the long sides (25a) and having a pair of short sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the field coil element (21), the field coil element comprising: a profile coil composed of a plurality of coaxially coaxially arranged coils, the plurality of coaxially coaxially coiled turns being wound around the annular peripheral portion of the electrically insulating coil, the profile coil having a first coil end (Ea, Eb) to be electrically connected to a conductor wire of a brush to provide electrical contact with the armature (5). ), the first coil end (Ea, Eb) of the profile coil extending therefrom, and a fastener integrally provided in the electrically insulating coil and configured to secure the first coil end (Ea, Eb ) of the profile coil.
[9" id="c-fr-0009]
The rotary electrical machine according to claim 8, further comprising: a reinforcement formed on one of the long sides (25a) of the first coil end (Ea, Eb) of the profile coil and acting to reinforce the rigidity to a force to be applied in the direction of the thickness of the first coil end (Ea, Eb).
[10" id="c-fr-0010]
The rotary electrical machine according to claim 9, wherein the reinforcement comprises a protruding member protruding from the first of the long sides (25a) of the first coil end (Ea, Eb) of the profile coil.
[11" id="c-fr-0011]
The rotary electric machine according to claim 9, wherein the reinforcement comprises a folded portion for providing a double thickness between the long sides (25a) of the first coil end (Ea, Eb) of the profile coil, the wire conductor being electrically connected to the folded portion.
[12" id="c-fr-0012]
The rotary electric machine according to claim 8, wherein the yoke (13) has a plurality of circumferentially mounted circumferential ring-mounted circumferential electrically insulating surface mounted pole cores, the coil has a plurality of portions respectively on the outer peripheries of the plurality. of pole cores, and each of the plurality of annular peripheral portions has a flange extending circumferentially therethrough, the flange of a portion of the plurality of annular peripheral portions on which the turns of the profile coils are mounted and that of another of the plurality of annular peripheral portions circumferentially adjacent thereto, are joined to each other to form a flange-connecting portion, the fastener being mounted to the flange portion collar connection.
[13" id="c-fr-0013]
The rotary electric machine according to claim 8, wherein at least the first coil end (Ea, Eb) of the profile coil is fixedly mounted on at least one of the yoke (13), pole, and the electrically insulating coil through an adhesive element.
[14" id="c-fr-0014]
14. A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and first and second pole cores mounted on the circumferential surface, each of the first and second pole cores having an outer periphery, a field coil element (21) operative to produce a magnetic field when energized, the field coil element (21) being composed of a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness between them substantially smaller than a width of the long sides (25a) and having a pair of small sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the field coil element (21), the field coil element (21) comprising t: a first profile coil composed of a plurality of turns coaxially arranged in layers, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the first pole core, a second composite profile coil a plurality of coaxially arranged coiled turns, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the second pole core, and a connecting portion continuing between a turn of the plurality of coils. coaxially arranged coils of the first profile coil and a turn of the plurality of coaxially arranged coaxial turns of the second profile coil, a position of the connection portion in a circumferential direction of the yoke (13). ) being determined according to at least one of the number of turns arranged in layers of man the coaxial coil of the first profile coil and the number of coaxially arranged coils of the first profile coil.
[15" id="c-fr-0015]
The rotary electrical machine according to claim 14, wherein the outer periphery of each of the first and second pole cores has a first corner and a second corner and are opposed to each other in an axial direction and a circumferential direction. of the yoke (13), a first end of the connecting portion extends from one of the plurality of coaxially coaxially arranged coils of the first profile coil at one of the first and second corners of the first pole core, and the other end of the connecting portion extends from one of the plurality of coaxially layered turns of the second profile coil to the other of the first and second corners of the second pole core.
[16" id="c-fr-0016]
The rotary electric machine according to claim 14, wherein a first end of the connecting portion extends from one of the plurality of coaxially arranged coaxial turns of the first profile coil to a predetermined position in one direction. axial direction of the yoke (13), and the other end of the connecting portion extends from one of the plurality of coaxially arranged coaxial turns of the second profile coil to the same predetermined position in the axial direction. the breech (13).
[17" id="c-fr-0017]
17. A rotating electrical machine for rotating a frame (5) on the basis of a magnetic field, the rotating electrical machine comprising: a yoke (13) having a circumferential surface and first and second pole cores mounted on the circumferential surface, each of the first and second pole cores having an outer periphery, a field coil element (21) operative to produce a magnetic field when energized, the field coil element (21) being composed of a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness between them substantially smaller than a width of the long sides (25a) and having a pair of small sides (25b, 25c), the rectangular connecting wire (25) being wound at the small sides (25b, 25c) in the field coil element (21), the field coil element (21) comprising t: a first profile coil composed of a plurality of turns coaxially arranged in layers, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the first pole core, a second composite profile coil a plurality of coaxially arranged coiled turns, the plurality of coaxially arranged coiled turns being wound around the outer periphery of the second pole core, and a connecting portion disposed in an axial direction of the yoke ( 13) so as to continue between a turn of the plurality of coaxially coaxially arranged turns of the first profile coil and a turn of the plurality of coaxially layered turns of the second profile coil, a length of of the connecting part in the axial direction of the cylinder head (13) being determined according to at least one of the number of turns arranged coaxially in layers of the first profile coil and the number of coaxially arranged coils of the first profile coil.
[18" id="c-fr-0018]
A method of manufacturing a field coil element (21) having a profile coil to be mounted on a pole core mounted on a circumferential surface of a yoke (13), the pole core having an outer periphery. the outer periphery having at least one first rounded corner, the method comprising the steps of: providing a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness between them substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), provide a coil reinforcement, the coil reinforcement having an outer periphery of identical shape to the outer periphery of the pole core, putting a first small surface of a first end of the rectangular connecting wire (25) in contact with the at least one rounded first side of the outer periphery of the coil reinforcement so that: one end of the first end of the rectangular connecting wire (25) is left on, and a predetermined angle is formed between a longitudinal direction of the rectangular connecting wire (25) and a portion of the outer periphery of the coil reinforcement opposite the rectangular connecting wire (25), and winding at the narrow sides (25b, 25c) the rectangular connecting wire (25) from its first end around the outer periphery of the coil reinforcement while a state of the first small surface of the first end of the rectangular connecting wire (25) which is in contact with the at least one rounded corner of the outer periphery of the coil reinforcement is maintained to form thus the profile coil composed of a plurality of coaxially arranged coils, the end of the rectangular connecting wire (25) serving as the coil end (Ea, Eb) of the coil of profile, and: mounting the profile coil on the outer periphery of the pole core of the cylinder head (13) so that the coil end (Ea, Eb) of the profile coil extends from a start point on the at least first rounded corner of the pole core in a direction parallel to a tangential direction of the starting point of the at least one rounded corner, the direction of extension of the coil end (Ea, Eb) of the profile coil being inclined with respect to an axial direction of the yoke (13) at a predetermined angle.
[19" id="c-fr-0019]
A method of manufacturing a field coil element (21) having first and second profile coils to be respectively mounted on first and second pole cores mounted on a circumferential surface of a yoke (13), each first and second pole cores having an outer periphery, the outer periphery having at least one first rounded corner, the method comprising the steps of: providing a rectangular connecting wire (25), the rectangular connecting wire (25) having a pair of opposite long sides (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), providing first and second reel frames, the first armature coil having an outer periphery of identical shape to the outer periphery of the first pole core, the second coil armature having a periphery outer shape identical to the outer periphery of the second pole core, put a first small surface of a first end of the rectangular connecting wire (25) in contact with the at least first rounded corner of the outer periphery of the first frame of coil and a first small surface of the other end of the rectangular connecting wire (25) in contact with the at least one rounded corner of the outer periphery of the second coil frame so that: one end of the first end of the wire rectangular connection (25) is left on, a first predetermined angle is formed between a longitudinal direction of the rectangular connecting wire (25) and a portion of the outer periphery of the first coil reinforcement opposite to the rectangular connecting wire (25) , one end of the other end of the rectangular connecting wire (25) is left on, a second predetermined angle is formed between a longitudinal direction of the rectangular connecting wire (25) and a part of the outer periphery of the second coil reinforcement opposite to the rectangular connecting wire (25), and winding at the small side (25b, 25c) the wire of rectangular connection (25) from its first end and its other end around the outer peripheries of the first and second coil frames while a state of the first small surface of the first end of the rectangular connecting wire (25), which is contact with the at least first rounded corner of the outer periphery of the first coil reinforcement and the state of the first small surface of the other end of the rectangular connecting wire (25), which is in contact with the at least first rounded corner of the outer periphery of the second coil reinforcement, are held to thereby form the first and second profile coils, each consisting of a plurality of coaxially arranged coils, the end of the first end of the rectangular connecting wire (25) serving as the first coil end (Ea, Eb) of the first profile coil, the tip of the at the other end of the rectangular connecting wire (25) serving as the second coil end (Ea, Eb) of the second profile coil, mounting the first profile coil on the outer periphery of the first pole core of the cylinder head (13). whereby the first coil end (Ea, Eb) of the first profile coil extends from a start point on the at least one first rounded corner of the first pole core in a parallel direction in a tangential direction of the start point from the at least one rounded corner, the extension direction of the first coil end (Ea, Eb) of the first profile coil being inclined with respect to an axial direction of the cylinder head (13) at the first angle determined, and mounting the second profile coil on the outer periphery of the second pole core of the yoke (13) so that the second coil end (Ea, Eb) of the second profile coil extends from a beginning on the at least first rounded corner of the second pole core in a direction parallel to a tangential direction of the start point of the at least first rounded corner, the direction of extension of the second coil end (Ea, Eb) of the second profile coil being inclined with respect to an axial direction of the yoke (13) at the second predetermined angle.
[20" id="c-fr-0020]
A method of manufacturing a field coil element (21) to be mounted on a circumferential surface of a yoke (13), the method comprising the steps of: providing a rectangular wire (25), the wire rectangular connecting member (25) having a pair of opposing long sides (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), winding at the small level sides (25b, 25c) the rectangular connecting wire (25) from both a first and the other end thereof to form: a first profile coil composed of a plurality of turns disposed in layers coaxially on the first end of the rectangular connecting wire (25), a second profile coil composed of a plurality of turns coaxially layered on the other end of the rectangular connecting wire (25), and part of e bonding continuing between a turn of the plurality of coaxially layered turns of the first profile coil and one of the plurality of coaxially layered turns of the second profile coil, and adjusting a circumferential position of the connecting portion as a function of at least one of the number of coaxially arranged turns of the first profile coil and the number of coaxially arranged coils of the first profile coil.
[21" id="c-fr-0021]
A method of manufacturing a field coil element (21) to be mounted on a circumferential surface of a cylinder head (13), the method comprising the steps of: providing a rectangular wire (25), the wire rectangular connecting member (25) having a pair of opposing long sides (25a) and a thickness therebetween substantially less than a width of the long sides (25a) and having a pair of short sides (25b, 25c), winding at the small level sides (25b, 25c) the rectangular connecting wire (25) from both a first end and the other end thereof to form: a first profile coil composed of a plurality of arranged turns in coaxial layers on the first end of the rectangular connecting wire (25), a second profile coil composed of a plurality of turns arranged in layers coaxially on the other end of the rectangular connecting wire (25), and a connecting portion continuing between a turn of the plurality of coaxially layered turns of the first profile coil and a turn of the plurality of coaxially layered turns of the second profile coil, and adjusting a the length of the connecting part in the axial direction of the yoke (13) as a function of at least one turn of the number of turns coaxially arranged in layers of the first profile coil and the number of turns arranged in layers of coaxial way of the first profile coil.

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同族专利:

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公开号 | 公开日

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KR20080071879A|2008-08-05|

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US8250738B2|2012-08-28|

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FR2912009A1|2008-08-01|

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US7952250B2|2011-05-31|

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US20100170084A1|2010-07-08|

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CN101882827A|2010-11-10|

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CN101237166A|2008-08-06|

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US20080179983A1|2008-07-31|

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CN101237166B|2011-05-11|

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US20100187936A1|2010-07-29|

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KR100906235B1|2009-07-07|

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CN101882827B|2012-12-05|

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DE102007041866A1|2008-08-14|

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FR3050082B1|2019-11-29|

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US7804217B2|2010-09-28|

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法律状态:
2017-09-25| PLFP| Fee payment|Year of fee payment: 11 |

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2018-09-24| PLFP| Fee payment|Year of fee payment: 12 |

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2019-09-26| PLFP| Fee payment|Year of fee payment: 13 |

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2021-06-11| ST| Notification of lapse|Effective date: 20210506 |

优先权:

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JP2007021462A|JP4888138B2|2007-01-31|2007-01-31|Method for manufacturing field coil of rotating electrical machine|

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JP2007021741A|JP4811286B2|2007-01-31|2007-01-31|Rotating electric machine and field coil manufacturing method|

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JP2007029979A|JP4910742B2|2007-02-09|2007-02-09|Rotating electric machine and field coil manufacturing method|

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FR0706287A|FR2912009A1|2007-01-31|2007-09-07|Rotary electric machine e.g. starter motor, for rotating armature, has edgewise coils, where crossover portion between coil end and link portion is arranged to be non-overlapped with convolutions of one of coils|

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