DESCRIPTION
TITLE OF THE INVENTION: COIL APPARATUS AND METHOD OF MANUFACTURING SAME
TECHNICAL FIELD
[0001] This invention relates to a coil device used in a power generator, an electric motor, a resolver or the like, and to a method of manufacturing the device.
BACKGROUND ART
[0002] In a conventional coil device for a resolver, terminal pins are inserted respectively into a plurality of slotted holes provided in a coil end connection section. The slotted holes are each provided with a constricted section and a round hole section. After winding the conducting wires of the coil ends around the terminal pins, the terminal pins are moved towards the inside of the stator and are fixed in the round hole sections. Consequently, slack is created in the conducting wires of the coil ends (see, for example, PTL 1). [0003] Furthermore, in a further coil device of a conventional resolver, a jig pin is inserted into a terminal pin holding section, whereupon an end conducting wire is brought into contact with the jig pin so as to apply a tension to the end conducting wire and is fixed to the terminal pin. When the jig pin is subsequently removed, slack is created in the conducting wire (see, for example, PTL 2).

CITATION LIST PATENT LITERATURE
[0004] [PTL 1] Japanese Patent Application Publication No. 2004-56903
[PTL 2] Japanese Patent Application Publication No. 2009-268230
SUMMARY OF THE INVENTION
PROBLEM TO BE SOLVED BY THE INVENTION
[0005] In the conventional coil device for a resolver disclosed in PTL 1, it has been necessary to carry out a step for moving the terminal pins inside the stator and fixing the terminal pins. Furthermore, since it is necessary to move each terminal pin to the round hole section along a previously manufactured slotted hole shape, then the amount of slack inevitably becomes greater, and it is also difficult to adjust the amount of slack, and therefore the conducting wires in the coil become liable to uncoil or to drop off from the terminal pins. Moreover, since the direction of slack of the conducting wires varies in the circumferential direction and the axial direction of the stator, it is difficult to create slack in a stable fashion, and the risk of disconnection of the conducting wires of the coil ends cannot be reduced. [0006] Furthermore, in the conventional coil device for a resolver disclosed in PTL 2, the conducting wires must make

direct contact with the jig pins, and therefore the conducting wires rub against the jig pins and there is risk of damage to the insulating film or disconnection.
[0007] This invention was devised in order to resolve the problem described above, an object thereof being to provide a coil device and method for manufacturing same whereby slack can be created easily and stably in end conducting wires of a coil group.
MEANS FOR SOLVING THE PROBLEM
[0008] The coil device according to the present invention is a coil device including: an iron core having a plurality of tooth sections; a coil group having a plurality of coil sections provided on the tooth sections, and a plurality of end conducting wire sections which are extracted from the coil sections; and a coil end connection section having a plurality of terminals to which the end conducting wire sections are connected, wherein the coil end connection section includes: a connection section main body which is fixed to the iron core and on which the terminals are provided; and a movable guide section which is connected to the connection section main body via an elastic deformation section, and which is engaged by the end conducting wire sections and moreover which guides the end conducting wire sections to the terminals.
Furthermore, the method for manufacturing a coil device according to this invention is a method for manufacturing a

coil device including: an iron core having a plurality of tooth sections; a coil group having a plurality of coil sections provided on the tooth sections, and a plurality of end conducting wire sections which are extracted from the coil sections; and a coil end connection section having a plurality of terminals to which the end conducting wire sections are connected, the method including: an elastic deformation step of elastically deforming an elastic deformation section provided on the coil end connection section and displacing a movable guide section connected to the elastic deformation section; a connection step of connecting the end conducting wire sections with the terminals by engaging the end conducting wire sections with the movable guide section; and a restoration step of creating slack in the end conducting wire sections by restoring the elastic deformation section and returning the movable guide section.
EFFECTS OF THE INVENTION
[0009] In the coil device and method for manufacturing same according to this invention, it is possible to create slack, easily and stably, in end conducting wire sections of a coil group, by elastically deforming an elastic deformation section to connect the end conducting wire sections with the terminals, and then restoring the elastic deformation sections.

BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Fig. 1 is a perspective drawing showing a stator according to a first embodiment of this invention.
Fig. 2 is a front surface diagram showing the stator in Fig. 1.
Fig. 3 is a perspective diagram illustrating a section of the coil end connection section in Fig. 1 along line III-III.
Fig. 4 is a perspective diagram illustrating a section of the coil end connection section in Fig. 1 along line IV-IV. Fig. 5 is a cross-sectional diagram along line V-V in Fig. 2.
Fig. 6 is a perspective drawing showing a state before installing a coil group on the iron core in Fig. 4.
Fig. 7 is a cross-sectional diagram showing a state before installing a coil group on the iron core in Fig. 5. Fig. 8 is a perspective diagram illustrating a state where the elastic deformation sections in Fig. 6 have been elastically deformed.
Fig. 9 is a cross-sectional diagram illustrating a state where the elastic deformation sections in Fig. 7 have been elastically deformed.
Fig. 10 is a perspective drawing showing a state where a coil group has been installed on the iron core in Fig. 8.
Fig. 11 is a perspective drawing showing a state where a coil group has been installed on the iron core in Fig. 9.
Fig. 12 is a perspective diagram showing a state where

the jig has been removed from the stator in Fig. 10.
Fig. 13 is a perspective diagram showing a state where the jig has been removed from the stator in Fig. 11.
Fig. 14 is an illustrative diagram depicting a schematic view of a principal portion of Fig. 11.
Fig. 15 is a perspective drawing showing the portion corresponding to Fig. 3 of the stator according to a second embodiment of this invention.
Fig. 16 is a perspective drawing showing the portion corresponding to Fig. 4 of the stator according to the second embodiment.
Fig. 17 is a cross-sectional drawing showing the portion corresponding to Fig. 5 of the stator according to the second embodiment.
Fig. 18 is an illustrative diagram depicting a schematic view of a principal portion of Fig. 10, viewed from the front surface.
DESCRIPTION OF EMBODIMENTS
[0011] Below, an embodiment of this invention is described with reference to the drawings taking a stator used in a resolver as an example.
First Embodiment
Fig. 1 is a perspective diagram showing a stator according to a first embodiment of this invention, and Fig. 2 is a front surface diagram showing the stator in Fig. 1. In

the drawings, the stator 1 has a ring-shaped iron core 2, an insulator 3 which is fixed to the iron core 2, and a coil group 4.
[0012] A plurality of tooth sections 2a projecting in an inward radial direction are provided on the inner circumference portion of the iron core 2. The tooth sections 2a are arranged at intervals apart in the circumferential direction of the iron core 2. Consequently, slot sections 2b are formed between the mutually adjacent tooth sections 2a. In other words, the tooth sections 2a and slot sections 2b are arranged alternately in the circumferential direction of the iron core 2.
[0013] The coil group 4 has a plurality of coil sections 4a in which a conducting wire is wound about a tooth section 2a, and a plurality of end conducting wire sections 4b which project from the coil sections 4a.
[0014] The insulator 3 has a coil installation section 3a which covers the periphery of the tooth sections 2a of the iron core 2, and a coil end connection section 3b which projects in an outward radial direction from a portion of the iron core 2 in the circumferential direction thereof. [0015] A plurality of terminal pins 5 (in this example, six pins) as terminals are fixed to the coil end connection section 3b. An intermediate section of each of the terminal pins 5 is embedded inside the coil end connection section 3b. Furthermore, a first end section of each of the terminal pins

5 projects to one side in the axial direction of the iron core 2 from the coil end connection section 3b. Furthermore, a second end section of each of the terminal pins 5 projects in the outward radial direction of the iron core 2 from the coil end connection section 3b. A corresponding end conducting wire section 4b is connected to the first end section of each of the terminal pins 5.
[0016] Fig. 3 is a perspective diagram showing a cross-section of the coil end connection section 3b in Fig. ■ 1 along line III-I1I, Fig. 4 is a perspective diagram showing a cross-section of the stator 1 in Fig. 1 along line IV-IV, and Fig. 5 is a cross-sectional diagram along line V-V in Fig. 2. [0017] The coil end connection section 3b includes a connection section main body 3c, a plurality of (in this example, two) elastic deformation sections 3d having an L shape fa U shape cut in half), a plurality of (in this example, three) movable guide sections 3e, a joining section 3f, and a plurality of (in this example, three) fixed guide sections (stationary sections) 3g.
[0018] The connection section main body 3c is fixed to the iron core 2 . Furthermore, all of the terminal pins 5 are provided on the connection section main body 3c. [0019] A through hole 7 having a square cross-section is provided in the coil end connection section 3b. The through hole 7 passes through the coil end connection section 3b in parallel with the axial direction of the iron core 2. The

connection section main body 3c is arranged on the opposite side of the through hole 7 from the iron core 2. [0020] The end conducting wire section 4b is arranged on a first end surface of the coil end connection section 3b in the axial direction of the iron core 2 (the surface from which the first end sections of the terminal pins 5 project), and crosses the opening of the through hole 7 on the side of the first end surface.
[0021] The elastic deformation sections 3d are arranged inside the opening of the coil end connection section 3b. Furthermore, the elastic deformation sections 3d are spring sections made from an elastic member which function as leaf springs that are capable of elastic deformation in the radial direction of the iron core 2. A first end section of each elastic deformation section 3d is fixed to the inner wall surface of the through hole 7. A second end section of the elastic deformation section 3d is connected to the joining section 3f.
[0022] The movable guide sections 3e are connected to the joining section 3f. In other words, the movable guide sections 3e are connected to the connection section main body 3c via the elastic deformation sections 3d, and the joining section 3f is interposed between the movable guide sections 3e and the elastic deformation sections 3d. The joining section 3f functions as a base which supports the movable guide sections

[0023] The movable guide sections 3e project to one side in the axial direction of the iron core 2 from the opening of the through hole 7 on the side of the first end surface. Furthermore, the movable guide sections 3e are disposed between the terminal pins 5 and the iron core 2. The end conducting wire sections 4b are engaged by the movable guide sections 3e. Consequently, the movable guide sections 3e guide the end conducting wire sections 4b to the corresponding terminal pins 5.
[0024] The movable guide sections 3e are displaceable in a direction which increases and decreases the reactive force generated by the tension of the end conducting wire sections 4b (the radial direction of the iron core 2), by deformation and restoration of the elastic deformation sections 3d. In other words, the movable guide sections 3e are displaceable in a direction towards the iron core 2, by elastic deformation of the elastic deformation sections 3d.
[0025] The dimension (width dimension) of the elastic deformation sections 3d and the movable guide sections 3e in the circumferential direction of the iron core 2 (the width direction of the coil end connection section 3b (the left/right direction in Fig. 2)) is smaller than the dimension (width dimension) of the joining section 3f in the same direction. The movable guide sections 3e and the elastic deformation sections 3d are arranged alternately in the circumferential direction of the iron core 2. In other words,

the elastic deformation sections 3d are arranged between the mutually adjacent movable guide sections 3e in the circumferential direction of the iron core 2. [0026] The fixed guide sections 3g are provided on the connection section main body 3c. Furthermore, the fixed guide sections 3g are provided on an edge portion of the through hole 7 on the side of the terminal pins 5. Moreover, the fixed guide sections 3g project towards one side in the axial direction of the iron core 2 from the first end surface of the coil end connection section 3b, and face the corresponding movable guide sections 3e.
[0027] Next, a method for manufacturing the stator 1 and in particular, a method for connecting the end conducting wire sections 4b to the terminal pins 5 will be described. The method for manufacturing a stator 1 according to the first embodiment includes: an elastic deformation step for deforming the elastic deformation sections 3d and displacing the movable guide sections 3e in a direction towards the iron core 2 (in the inward radial direction of the iron core 2), a connection step for engaging the end conducting wire sections 4b with the movable guide sections 3e and connecting the end conducting wire sections 4b with the terminal pins 5, and a restoration step for restoring the elastic deformation sections 3d and returning the movable guide sections 3e in a direction away from the iron core 2 (the outward radial direction of the iron core 2) .

[0028] Fig. 6 is a perspective diagram illustrating a state before installing a coil group 4 on the iron core 2 in Fig. 4, Fig. 7 is a cross-sectional diagram illustrating a state before installing a coil group 4 on the iron core 2 in Fig. 5, Fig. 8 is a perspective diagram illustrating a state where the elastic deformation sections 3d in Fig. 6 have been elastically deformed and Fig. 9 is a cross-sectional diagram illustrating a state where the elastic deformation sections 3d in Fig. 7 have been elastically deformed. [0029] In the elastic deformation step, a jig 6 for elastically deforming the elastic deformation sections 3d by enlarging the gap between the joining section 3f and the inner wall surface of the through hole 7 is prepared. A plurality of pin sections 6a are provided in the jig 6. The thickness (diameter) of the pin sections 6a is greater than the dimension of the gap between the joining section 3f and the inner wall surface of the through hole 7.
[0030] By providing a through hole 7 in the coil end connection section 3b, it is possible to insert the pin sections 6a in between the joining section 3f and the connection section main body 3c, from the side of the elastic deformation section 3d. In the elastic deformation step, by inserting the pin sections 6a in between the joining section 3f and the inner wall surface of the through hole 7, the elastic deformation sections 3d are caused to deform elastically and the movable guide sections 3e are displaced in

a direction towards the iron core 2.
[0031] Fig. 10 is a perspective diagram illustrating a state where a coil group 4 has been installed on the iron core 2 in Fig. 8, and Fig. 11 is a cross-sectional diagram illustrating a state where a coil group 4 has been installed on the iron core 2 in Fig. 9. In the connecting step, after installing the coil sections 4a on the corresponding tooth sections 2a, the end conducting wire sections 4b are connected to, in other words, wound about and fixed to, the corresponding terminal pins 5. In this case, the end conducting wire sections 4b are engaged with the movable guide sections 3e in a tensioned state corresponding to the specifications of the conducting wires.
[0032] Fig. 12 is a perspective diagram illustrating a state where the j ig 6 has been removed from the stator 1 in Fig. 10 and Fig. 13 is a cross-sectional diagram illustrating a state where the jig 6 has been removed from the stator 1 in Fig. 11. In the restoration step, the pin sections 6a are pulled out from the coil end connection section 3b, and the j ig 6 is removed from the stator 1. Consequently, the elastic deformation sections 3d are restored and the movable guide sections 3e return in a direction away from the iron core 2 (in a direction which reduces the reaction force generated by the tension in the end conducting wire sections 4b). [0033] In a stator 1 of this kind, by elastically deforming the elastic deformation sections 3d to connect the

end conducting wire sections 4b with the terminal pins 5, and then restoring the elastic deformation sections 3d, it is possible to create slack, easily and stably, in the end conducting wire sections 4b.
Furthermore, since the end conducting wire sections 4b do not directly contact the pin sections 6a of the jig 6, the end conducting wire sections 4b do not rub against the pin sections 6a and it is possible to prevent damage to the insulating layer and disconnection of the end conducting wire sections 4b.
[0034] Furthermore, by adjusting the amount of deformation of the elastic deformation sections 3d, it is possible to readily adjust the amount of slack of the end conducting wire sections 4b.
Moreover, since the direction of the slack in the end conducting wire sections 4b is reliably set to the outward direction of the movable guide sections 3e, then the attitude of the end conducting wire sections 4b is made stable and the risk of disconnection of the end conducting wire sections 4b can be reduced.
[0035] Moreover, since the pin sections 6a are inserted in between the joining section 3f and the connection section main body 3c and the elastic deformation sections 3d are deformed elastically, then it is possible to finely adjust the amount of deformation of the movable guide sections 3e, easily, by changing the thickness of the pin sections 6a. Consequently,

the amount of slack in the end conducting wire sections 4b is adjusted and it is possible to prevent the end conducting wire sections 4b from unwinding and falling off.
[0036] Furthermore, since the direction of installation of the jig 6 (the direction of insertion of the pin sections 6a) is the same as the direction in which the iron core 2 is installed on the winding device (not illustrated) for the winding step of the coil group 4 (the axial direction of the iron core 2), then by previously providing the jig 6 on the winding machine, it is possible to carry out the step for installing the iron core 2 on the winding machine for the winding step, and the elastic deformation step, simultaneously.
[0037] Moreover, Fig. 14 is an illustrative diagram illustrating a schematic view of a principal portion of Fig. 11. The movable guide sections 3e are displaced at an acute angle with respect to a direction which reduces the reaction force received due to the tension in the end conducting wire sections 4b contacted thereby. Therefore, during winding, a force acting towards the base of the movable guide sections 3e is generated in the end conducting wire sections 4b by the tension in the end conducting wire sections 4b, and it is possible to prevent the end conducting wire sections 4b from falling off the movable guide sections 3e.
[0038] Moreover, since the fixed guide sections 3g are provided on the coil end connection section 3b, then it is

possible to prevent the pin sections 6a of the jig 6 from becoming detached, and the end conducting wire sections 4b can be protected. Furthermore, it is possible to create slack more reliably by winding the end conducting wire sections 4b in one revolution about both the movable guide sections 3e and the fixed guide sections 3g (a different engagement mode to that of the first embodiment). [0039] Second Embodiment
Next, Fig. 15 is a perspective diagram showing a portion corresponding to Fig. 3 of the stator according to a second embodiment of the invention, Fig. 16 is a perspective diagram showing a portion corresponding to Fig. 4 of the stator according to the second embodiment, and Fig. 17 is a cross-sectional diagram of a portion corresponding to Fig. 5 of a stator according to the second embodiment. [0040] In the first embodiment, L-shaped elastic deformation sections 3d are described, and in the second embodiment, U-shaped elastic deformation sections 3h are used. The rest of the configuration of the rotary electric machine is similar or identical to that of the first embodiment. [0041] By adopting a configuration of this kind, it is possible to extend the length of the elastic deformation section 3h, compared to the first embodiment, and the movable guide sections 3e can be supported in a flexible manner. Therefore, the amount of displacement of the movable guide section 3e can be enlarged.

Furthermore, there is no need to configure the insulator 3 including the elastic deformation section 3h from an elastic member having high flexibility, and the restrictions on the material used can be eased.
[0042] In the first and second embodiments, the movable guide sections 3e are connected to a common joining section 3f, but the movable guide sections may also be connected to elastic deformation sections of the same number as the movable guide sections, either directly or via joining sections of the same number as the movable guide sections. In other words, the movable guide sections may be made displaceable respectively in independent fashion.
Furthermore, in the first and second embodiments, the elastic deformation sections 3d, 3h are arranged between mutually adjacent movable guide sections 3e in the width direction of the coil end connection section 3b, but the elastic deformation sections 3d, 3h do not necessarily have to be provided between the movable guide sections, and the mutually adjacent elastic deformation sections may be integrated into a single body, for example. In order to make elastic deformation easier, the width dimension of the elastic deformation sections is desirably smaller than the width dimension of the joining section.
Moreover, in the first and second embodiments, the fixed guide sections 3g are provided on the coil end connection sections 3b, but the fixed guide sections 3g can be omitted.

Moreover, Fig. 18 is an illustrative diagram illustrating a schematic view of a principal portion of Fig. 10, from the front side. The direction of displacement of the movable guide sections by elastic deformation of the elastic deformation sections may be a direction in a superior angle range a based on the end conducting line sections which are engaged by the movable guide sections, and is not necessarily a direction towards the iron core. For example, in the case of the first embodiment, it is possible to rotate the movable guide sections and the related structure thereof through 90 degrees, by changing the manner of engaging the end conducting line sections with the movable guide sections, from both sides to one side.
Therefore, the elastic force generated by the elastic deformation of the elastic deformation sections may also act in the direction of an inferior angle range p based on the end conducting wire sections which are engaged by the movable guide sections. Furthermore, in the elastic deformation step in the method for manufacturing a coil device according to this invention, the movable guide sections may be displaced in the direction of a superior angle range a based on the end conducting wire sections which are engaged by the movable guide sections. Moreover, in the restoration step, the movable guide sections may be returned in the direction of an inferior angle range p based on the end conducting line sections which

are engaged by the movable guide sections.
Furthermore, in the first and second embodiments, the coil sections 3a are arranged on the inside of the iron core 2, but this invention can also be applied to a stator in which the coil sections are arranged on the outside of the iron core. In other words, a configuration in which the inner diameter side and outer diameter side of Fig. 1 and Fig. 2 are inverted may be adopted. Furthermore, a configuration wherein the coils are deployed in a band shape may also be adopted.
Moreover, the embodiments of the invention were described in relation to a stator of a resolver, but needless to say, this invention can also be applied to a coil device which is not known normally as a stator, such as a movable core-type electromagnetic actuator.

CLAIMS [Claim 1] A coil device, comprising:
an iron core having a plurality of tooth sections;
a coil group having a plurality of coil sections provided on the tooth sections, and a plurality of end conducting wire sections which are extracted from the coil sections; and
a coil end connection section having a plurality of terminals to which the end conducting wire sections are connected, wherein
the coil end connection section includes:
a connection section main body which is fixed to the iron core and on which the terminals are provided; and
a movable guide section which is connected to the connection section main body via an elastic deformation section, and which is engaged by the end conducting wire sections and moreover which guides the end conducting wire sections to the terminals.
[Claim 2] The coil device according to claim 1, wherein the movable guide section is displaceable in a direction in a superior angle range based on the end conducting wire sections, which are engaged by the movable guide section, due to elastic deformation of the elastic deformation section.
[Claim 3] The coil device according to claim 1 or 2, wherein a through hole is provided in the coil end connection

section;
the elastic deformation section is arranged inside the through hole; and
a jig which elastically deforms the elastic deformation section can be inserted into the through hole.
[Claim 4] The coil device according to any one of claims 1 to 3, wherein
the elastic deformation section is spring section made from elastic member; and
an elastic force generated by elastic deformation of the elastic deformation section is applied in a direction of an inferior angle range based on the end conducting wire sections, which are engaged by the movable guide section.
[Claim 5] A method for manufacturing a coil device including:
an iron core having a plurality of tooth sections;
a coil group having a plurality of coil sections provided on the tooth sections, and a plurality of end conducting wire sections which are extracted from the coil sections; and
a coil end connection section having a plurality of terminals to which the end conducting wire sections are connected,
the method comprising:
an elastic deformation step of elastically deforming an elastic deformation section provided on the coil end

connection section and displacing a movable guide section connected to the elastic deformation section;
a connection step of connecting the end conducting wire sections with the terminals by engaging the end conducting wire sections with the movable guide section; and
a restoration step of creating slack in the end conducting wire sections by restoring the elastic deformation section and returning the movable guide section.
[Claim 6] The method for manufacturing a coil device according to claim 5, wherein
in the elastic deformation step, the movable guide section is displaced in a direction of a superior angle range based on the end conducting wire sections, which are engaged by the movable guide section; and
in the restoration step, the movable guide section is returned in a direction of an inferior angle range based on the end conducting wire sections which are engaged by the movable guide section.
[Claim 7] The method for manufacturing a coil device according to claim 5 or claim 6, wherein
in the elastic deformation step, the elastic deformation section is elastically deformed by inserting a jig into the coil end connection section; and
in the restoration step, the elastic deformation section

is restored by removing the jig from the coil end connection section.