CN115411896A - Method for manufacturing stator - Google Patents

Method for manufacturing stator Download PDF

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Publication number
CN115411896A
CN115411896A CN202210552805.1A CN202210552805A CN115411896A CN 115411896 A CN115411896 A CN 115411896A CN 202210552805 A CN202210552805 A CN 202210552805A CN 115411896 A CN115411896 A CN 115411896A
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CN
China
Prior art keywords
stator
substrate
manufacturing
cover
mounting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202210552805.1A
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Chinese (zh)
Inventor
吴耿彰
颜国智
游欣璋
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nidec Corp
Original Assignee
Nidec Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nidec Corp filed Critical Nidec Corp
Publication of CN115411896A publication Critical patent/CN115411896A/en
Pending legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto

Abstract

The present invention provides a method for manufacturing a stator, the stator is arranged opposite to a rotor rotating around a central shaft, the method for manufacturing the stator comprises the following steps: a first step of mounting a ring-shaped stator cover on an insulating substrate having a circuit pattern, mounting a stator core inside the stator cover of the substrate, mounting a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin into the inside of the stator cover; a third step of fixing the stator cover, the stator core, and the coil to the substrate by heating and curing the thermosetting resin; a fourth step of mounting an electronic component on the substrate and connecting the electronic component to the circuit pattern; and a fifth step of cutting the mounting region of the substrate, on which the stator cover, the stator core, the coil, and the electronic component are mounted, from a non-mounting region around the mounting region of the substrate.

Description

Method for manufacturing stator
Technical Field
The present invention relates to a method of manufacturing a stator disposed to face a rotor that rotates about a central axis.
Background
Conventionally, a motor having a stator disposed to face a rotor that rotates about a central axis is known.
For example, patent document 1 discloses an axial gap motor including a stator integrally formed of a molded resin in a state in which nine core members in which a winding is wound around an insulator covering a tooth portion of a remaining stator core are annularly connected. In the stator of patent document 1, a shaft insertion hole into which a shaft is inserted, a pair of bearing receiving holes formed continuously with the shaft insertion hole and respectively receiving bearings, a substrate arrangement stepped portion in which a circuit substrate is arranged, and a pair of cover fitting stepped portions in which a bracket cover is fitted are integrally formed of a molded resin.
Documents of the prior art
Patent literature
Patent document 1: japanese patent laid-open No. 2012-182862
Disclosure of Invention
Problems to be solved by the invention
However, in patent document 1, there is no description about an electronic component mounted on a circuit board, and there is no specific description about a method for manufacturing a stator, and therefore, there is still room for improvement with respect to easily manufacturing a stator in which an electronic component is mounted on a circuit board.
The invention aims to provide a method for manufacturing a stator, which can easily manufacture the stator with electronic components mounted on a circuit substrate.
Means for solving the problems
A method for manufacturing a stator according to the present invention is a method for manufacturing a stator disposed to face a rotor that rotates about a central axis, the method including: a first step of mounting a ring-shaped stator cover on an insulating substrate having a circuit pattern, mounting a stator core inside the stator cover on the substrate, mounting a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin into the inside of the stator cover; a third step of fixing the stator cover, the stator core, and the coil to the substrate by heating and curing the thermosetting resin; a fourth step of mounting an electronic component on the substrate and connecting the electronic component to the circuit pattern; and a fifth step of cutting a mounting region of the substrate, on which the stator cover, the stator core, the coil, and the electronic component are mounted, from a non-mounting region around the mounting region of the substrate.
Effects of the invention
According to the present invention, a stator in which an electronic component is mounted on a circuit board can be easily manufactured.
Drawings
Fig. 1 is a perspective view of an axial motor including a stator according to an embodiment of the present invention.
Fig. 2 is an exploded perspective view of an axial motor including a stator according to an embodiment of the present invention.
Fig. 3 is a perspective view of a stator coil assembly of the stator according to the embodiment of the present invention.
Fig. 4 is a perspective view of a stator cover of a stator according to an embodiment of the present invention.
Fig. 5 is a flowchart illustrating a method of manufacturing a stator according to an embodiment of the present invention.
Fig. 6 is an exploded perspective view illustrating a first step of a method of manufacturing a stator according to an embodiment of the present invention.
Fig. 7 is a perspective view showing a first step of the method for manufacturing a stator according to the embodiment of the present invention.
Fig. 8 is a perspective view showing a second step and a third step of the method for manufacturing a stator according to the embodiment of the present invention.
Fig. 9 is a perspective view showing a fourth step of the method for manufacturing a stator according to the embodiment of the present invention.
Fig. 10 is a perspective view showing a fifth step of the method for manufacturing a stator according to the embodiment of the present invention.
In the figure:
1-rotor, 2-stator, 11-shaft, 12-yoke, 13-magnet, 14-yoke, 15-bearing, 16-encoder disk, 21-stator coil assembly, 23-front cover, 24-rear cover, 25-front bolt, 26-rear bolt, 100-axial motor, 211-stator cover, 211A-groove, 211B-fastening hole, 212-base plate, 212A-coupling portion, 212B-tool frame base plate, 212C-main base plate, 212D-slit portion, 212E-burr, 212F-fitting hole, 212G-cut surface, 213-stator core, 214-coil, 215-magnetic sensor, 216-encoder, 217-power signal terminal group, 217A-connector, 217B-power connector, 218-resin portion, 219-bearing seat.
Detailed Description
An axial motor and a stator provided with the stator according to an embodiment of the present invention will be described below with reference to the drawings. The scope of the present invention is not limited to the following embodiments, and may be arbitrarily changed within the scope of the technical idea of the present invention. In the drawings below, in order to facilitate understanding of the respective structures, scales, numbers, and the like of the respective structures may be different from scales, numbers, and the like of the actual structures.
< Structure of axial Motor >
The structure of an axial motor 100 having a stator 2 according to an embodiment of the present invention will be described in detail with reference to fig. 1 and 2.
The axial motor 100 includes a rotor 1 that is rotationally driven, a stator 2 for rotating the rotor 1, and a bearing 15.
The rotor 1 includes a shaft 11, a yoke 12, a magnet 13, a yoke 14, and an encoder disk 16.
The shaft 11 is a rotary shaft (central shaft) through which the yoke 12, the encoder disk 16, the stator coil assembly 21, and the front cover 23 are inserted to rotate the rotor 1 relative to the stator 2.
The yoke 12 is disposed facing one surface (upper surface in fig. 2) of the stator coil assembly 21 in the rotation axis direction, and is attached to the shaft 11.
The magnets 13 are arranged in the circumferential direction on the surface of the yoke 12 facing the stator coil assembly 21, and arranged in the circumferential direction on the surface of the yoke 14 facing the stator coil assembly 21.
The yoke 14 is disposed to face the other surface (lower surface in fig. 2) of the stator coil assembly 21 in the rotation axis direction, and is attached to the shaft 11.
The encoder disk 16 is provided on a surface of the stator coil assembly 21 facing the yoke 14.
The stator 2 is disposed to face the rotor 1 in the rotation axis direction, and includes a stator coil assembly 21, a front cover 23, and a rear cover 24.
The stator coil assembly 21 is provided between the yoke 12 and the yoke 14. Stator coil assembly 21 is disposed opposite to rotor 1 in the central axis direction. The detailed structure of stator coil assembly 21 will be described later.
The front cover 23 receives the yoke 12, and fastens the stator coil assembly 21 by a front bolt 25.
The back cover 24 receives the yoke 14, and fastens the stator coil assembly 21 by a back bolt 26.
The bearing 15 is provided on the side of the stator coil assembly 21 facing the yoke 12 and the side facing the yoke 14, and rotatably supports the shaft 11.
< Structure of stator coil Assembly >
The structure of the stator coil assembly 21 of the stator 2 according to the embodiment of the present invention will be described in detail with reference to fig. 2 to 4.
The stator coil assembly 21 includes a stator cover 211, a substrate 212, a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC216, a power supply signal terminal group 217, and a bearing housing 219.
The stator cover 211 is annular. On the stator cover 211, groove portions 211A are provided at intervals of 90 degrees in the circumferential direction. The stator cover 211 is provided with fastening holes 211B between the groove portions 211A, and the fastening holes 211B are pressed by front bolts 25 for fastening the front cover 23 and rear bolts 26 for fastening the rear cover 24.
The substrate 212 is made of an insulating material, and includes a coupling portion 212A and a main substrate 212C. A conductive circuit pattern, not shown, is formed on the main substrate 212C by printing, and a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC216, a power supply signal terminal group 217, and a bearing housing 219 connected to the circuit pattern are mounted thereon.
The stator cores 213 are radially attached to the inside of the stator cover 211 of the main substrate 212C around the shaft 11. A plurality of stator cores 213 are attached to the main substrate 212C at intervals in the circumferential direction.
The coil 214 is mounted around the stator core 213 and connected to the circuit pattern of the main substrate 212C. The number of stator cores 213 and coils 214 is not limited to the number shown in fig. 3, and may be any number as long as one or more coils are provided.
The magnetic sensor 215 is mounted at a position farther from the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21 of the main substrate 212C. The magnetic sensor 215 is Surface-mounted on the main substrate 212C by SMT (Surface Mount Technology). The magnetic sensor 215 detects the magnetic field of the coil 214, and outputs an electric signal corresponding to the detection result to the connector 217A via the circuit pattern of the main substrate 212C.
The encoder sensor IC216 is mounted on the main board 212C at a position closer to the shaft 11 (center axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21. The encoder sensor IC216 is surface-mounted on the main substrate 212C by SMT. The encoder sensor IC216 detects the position of the rotor 1 by reading the encoder disk 16, and outputs an electric signal corresponding to the detection result to the connector 217A via the circuit pattern of the main substrate 212C.
The power signal terminal group 217 is constituted by a connector 217A and a power connector 217B. The power signal terminal group 217 is surface-mounted to the main substrate 212C by SMT.
The connector 217A is mounted on the main substrate 212C. A signal terminal, not shown, of the connector 217A is connected to the circuit pattern of the main board 212C, and is connected to the magnetic sensor 215 and the encoder sensor IC216 via the circuit pattern of the main board 212C. The connector 217A is fitted to an object-side connector, not shown, and outputs an electric signal output from the magnetic sensor 215 or the encoder sensor IC216 to the outside.
The power connector 217B is mounted on the main substrate 212C. The power supply terminal, not shown, of the power supply connector 217B is connected to the circuit pattern of the main board 212C, and is connected to the coil 214 via the circuit pattern of the main board 212C. The power connector 217B is fitted to an unillustrated object-side connector and supplies power to the coil 214.
The bearing housing 219 is mounted to the main substrate 212C. The bearing housing 219 is inserted with the shaft 11 and holds the bearing 15.
< method for manufacturing stator >
A method of manufacturing the stator 2 according to the embodiment of the present invention will be described in detail with reference to fig. 2 and 5 to 10. In fig. 7, the tool frame base plate 212B is not shown.
First, a substrate 212 shown in fig. 6 is prepared, and the substrate 212 includes a coupling portion 212A for coupling the main substrate 212C and the tool frame substrate 212B to each other at a slit portion 212D.
Here, the substrate 212 includes a coupling portion 212A, a tool frame substrate 212B, and a main substrate 212C.
The main substrate 212C includes a fitting hole 212F that penetrates the substrate 212 in the plate thickness direction and into which the stator core 213 is fitted. The fitting holes 212F are provided radially about a central axis through which the shaft 11 is inserted. A slit portion 212D penetrating in the plate thickness direction of the substrate 212 is provided between the tool frame substrate 212B and the main substrate 212C.
Next, as shown in fig. 6, a ring-shaped stator cover 211 is attached to an insulating main board 212C having a circuit pattern, a stator core 213 is attached to the inside of the stator cover 211 of the main board 212C, a coil 214 is attached to the periphery of the stator core 213, and the coil 214 is connected to the circuit pattern of the main board 212C (first step) (S1). This brings about the state shown in fig. 7.
In the first step, the stator cover 211 is attached to the main substrate 212C by engaging the coupling portion 212A with the groove portion 211A provided in the stator cover 211 and inserting the stator cover 211 into the slit portion 212D. This allows stator cover 211 to be easily positioned on substrate 212.
Further, in the first step, the stator core 213 is fitted into the fitting hole 212F, whereby the stator core 213 is mounted on the main substrate 212C. Thereby, the stator core 213 can be easily positioned with respect to the main substrate 212C.
Next, as shown in fig. 8, a liquid thermosetting resin is injected into a gap between the stator cover 211 and the coil 214 inside the stator cover 211 (second step) (S2).
Next, the thermosetting resin is heated and cured to form the resin portion 218, and the stator cover 211, the stator core 213, and the coil 214 are fixed to the main substrate 212C (third step) (S3). By forming the resin portion 218 by heating a thermosetting resin before the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are mounted on the main substrate 212C, it is possible to prevent the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 from being damaged by heating.
Next, as shown in fig. 9, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 as electronic components are surface-mounted on the main substrate 212C with the state thereof reversed with respect to that shown in fig. 8, and connected to the circuit pattern of the main substrate 212C (fourth step) (S4). At this time, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are surface-mounted on the main substrate 212C by an automatic machine such as a chip mounter. The tool frame base plate 212B disposed around the main base plate 212C is supported by the robot when being conveyed in the robot. By providing the tool frame substrate 212B, the substrate 212 can be easily positioned on a conveyor in the robot.
Next, as shown in fig. 10, the main board 212C, which is the mounting area where the stator cover 211, the stator core 213, the coil 214, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are mounted, is cut off from the tool frame board 212B, which is the non-mounting area around the main board 212C, by cutting the connecting portion 212A (a fifth step) (S5). In this way, since the main board 212C and the tool frame board 212B can be cut by the cutting connection portion 212A, the main board 212C and the tool frame board 212B can be easily cut.
By cutting the coupling portion 212A, a burr 212E remains in the tool frame substrate 212B, and a burr also remains in a cut surface 212G of the coupling portion 212A of the stator coil assembly 21, and the cut surface 212G becomes a fracture surface.
The stator 2 is manufactured so as to have the arrangement shown in fig. 2, using the stator coil assembly 21 manufactured by the manufacturing method described above.
As described above, according to the present embodiment, by performing the fourth step of attaching the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 to the main substrate 212C and connecting the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 to the circuit pattern after the third step of fixing the stator cover 211, the stator core 213, and the coil 214 to the main substrate 212C by heating and curing the thermosetting resin, it is possible to prevent the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 from being heated at a high temperature by heating at the time of curing the thermosetting resin, and it is possible to easily manufacture the stator coil assembly 21 in which the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are attached to the main substrate 212C.
Further, according to the present embodiment, in the fourth step, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are surface-mounted on the main board 212C, so that the operation of connecting the magnetic sensor 215, the encoder sensor IC216, the power supply signal terminal group 217, and the circuit pattern of the main board 212C to the main board 212C can be automated by an automated SMT line, and the number of steps can be significantly reduced, and the manufacturing cost can be reduced.
The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the present invention is defined by the claims, not by the embodiments described above, and is intended to include all modifications within the meaning and scope equivalent to the claims.
Specifically, in the above embodiment, the stator coil assembly 21 is provided in the axial flux motor 100, but the present invention is not limited to this, and the stator coil assembly 21 may be provided in a motor other than the axial flux motor.
In the above embodiment, the stator core 213 is provided, but the present invention is not limited to this, and the stator core 213 may not be provided.
In the above embodiment, the electronic components such as the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are surface-mounted on the main substrate 212C, but the present invention is not limited thereto, and the electronic components may be surface-mounted on the main substrate by a mounting method other than surface mounting such as through-hole mounting.
In the above embodiment, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are surface-mounted on the main substrate 212C by an automatic machine, but the present invention is not limited thereto, and the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 may be mounted on the main substrate 212C by a manual operation.
In the above embodiment, the magnetic sensor 215, the encoder sensor IC216, and the power supply signal terminal group 217 are mounted on the main board 212C as electronic components, but the present invention is not limited thereto, and any electronic components may be mounted on the main board as necessary.
In the above embodiment, the magnetic sensor 215 is mounted at a position farther from the shaft 11 (center axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21, and the encoder sensor IC216 is mounted at a position closer to the shaft 11 (center axis) than the stator core 213, but the present invention is not limited thereto, and the magnetic sensor and the encoder may be mounted at any position of the main substrate.

Claims (10)

1. A method of manufacturing a stator that is disposed to face a rotor that rotates about a central axis, the method comprising:
a first step of mounting a ring-shaped stator cover on an insulating substrate having a circuit pattern, mounting a stator core inside the stator cover on the substrate, mounting a coil around the stator core, and connecting the coil to the circuit pattern;
a second step of injecting a liquid thermosetting resin into the inside of the stator cover;
a third step of fixing the stator cover, the stator core, and the coil to the substrate by heating and curing the thermosetting resin;
a fourth step of mounting an electronic component on the substrate and connecting the electronic component to the circuit pattern; and
a fifth step of cutting a mounting region of the substrate on which the stator cover, the stator core, the coil, and the electronic component are mounted from a non-mounting region around the mounting region of the substrate.
2. The method of manufacturing a stator according to claim 1,
in the fourth step, the electronic component is surface-mounted on the substrate.
3. The method of manufacturing a stator according to claim 1 or 2,
the method further includes a step of preparing the substrate having a coupling portion for coupling the mounting region and the non-mounting region at a slit portion provided between the mounting region and the non-mounting region of the substrate and penetrating in a plate thickness direction.
4. The method of manufacturing a stator according to claim 3,
in the first step, the stator cover is mounted on the substrate by engaging the coupling portion with a groove portion provided in the stator cover and inserting the stator cover into the slit portion.
5. The method of manufacturing a stator according to claim 3 or 4,
in the fifth step, the mounting region is cut from the non-mounting region by cutting the connection portion.
6. The method of manufacturing a stator according to any one of claims 1 to 5,
in the fourth step, a connector including a power supply terminal and a signal terminal is mounted on the substrate as the electronic component, and the power supply terminal and the signal terminal are connected to the circuit pattern.
7. The method of manufacturing a stator according to any one of claims 1 to 6,
in the fourth step, a sensor for detecting a position of the rotor is mounted on the substrate as the electronic component, and a terminal portion of the sensor is connected to the circuit pattern.
8. The method of manufacturing a stator according to any one of claims 1 to 7,
in the first step, the stator core is mounted on the substrate by fitting the stator core into a fitting hole provided in the substrate and penetrating in a plate thickness direction.
9. The method of manufacturing a stator according to any one of claims 1 to 8,
the stator and the rotor are disposed to face each other in the central axis direction.
10. The method of manufacturing a stator according to any one of claims 1 to 9,
in the fourth step, the electronic component is mounted at a position closer to the central axis or farther from the central axis than the stator core in the radial direction of the stator.
CN202210552805.1A 2021-05-27 2022-05-19 Method for manufacturing stator Pending CN115411896A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2021089596A JP2022182193A (en) 2021-05-27 2021-05-27 Method for manufacturing stator
JP2021-089596 2021-05-27

Publications (1)

Publication Number Publication Date
CN115411896A true CN115411896A (en) 2022-11-29

Family

ID=84158486

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202210552805.1A Pending CN115411896A (en) 2021-05-27 2022-05-19 Method for manufacturing stator

Country Status (2)

Country Link
JP (1) JP2022182193A (en)
CN (1) CN115411896A (en)

Also Published As

Publication number Publication date
JP2022182193A (en) 2022-12-08

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