JP2000050583A - Manufacture of stator of wheel-in motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an easy manufacturing method of a stator of a thin, compact, and high-performance wheel-in motor. SOLUTION: This manufacturing method includes a welding step (S10) which forms a split stator core, by welding plural sheets of electromagnetic steel sheets while pressure-welding them, a coil winding step (S101) which winds round line material on a core while processing it into angle line material to make it into a split stator piece, a coil molding step (S102) which pressure the wound angle line material equally from both its sides and pairs it into specified form, a stator combining step (S103) which combines each split stator piece into ring form, a connecting step (S104) which connects the relevant coil terminals of each split stator piece witch each other, and a molding step (S105), which performs resin injection and performs permanent fixing of the stator form in the condition in that each split stator piece combined in ring form is accommodated in a mold and that the shape is fixed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a stator for a wheel-in motor, and more particularly to an improvement in a method for manufacturing a stator for easily manufacturing a thin, compact and high-performance wheel-in motor.

[0002]

2. Description of the Related Art Conventionally, wheel-in motors have been proposed to improve the driving efficiency when wheels are driven by an electric motor, and are mainly used for driving wheels of electric vehicles. It has also been proposed to utilize torque-assisting and 4WD functions when starting an engine-driven vehicle, and to improve vehicle motion stabilization by controlling torque distribution between left and right wheels.

Conventionally, various methods for manufacturing a rotating electric machine having the same driving principle as a wheel-in motor have been proposed. For example, Japanese Patent Laying-Open No. 7-298522 discloses a configuration in which a laminated iron core is divided, wound, and then assembled in an annular shape. Japanese Patent Application Laid-Open Nos. 57-34755 and 58-212351 disclose techniques for integrating split stators by resin molding. These techniques have been proposed to obtain a rotating electric machine with high performance and easy assembly.

[0004]

However, the wheel-in motor is limited in size, particularly in thickness and diameter, depending on the size of wheels used. Therefore, it is required to design and manufacture a high-performance wheel-in motor as compact and thin as possible, and to manufacture the wheel-in motor more easily.

The present invention has been made in view of the above-mentioned conventional problems, and has as its object to provide a method of manufacturing a wheel-in motor stator capable of easily manufacturing a thin, compact, high-performance wheel-in motor. Is to do.

[0006]

In order to achieve the above object, a first invention is a method of manufacturing a stator for a wheel-in motor, wherein a plurality of electromagnetic steel sheets are pressed against each other while being pressed against each other. Welding to form a divided stator core having at least one tooth, a coil winding step of forming a divided stator piece by winding a round wire into a square wire while winding the divided stator core, A coil forming step of pressing the swollen portion of the coil evenly from both sides to shape it into a predetermined shape, a stator assembling step of combining the divided stator pieces into a ring shape, and each of the divided stators combined in a ring shape A connection step for connecting the relevant coil terminals of the piece and each of the division steps combined in a ring A mold performing the permanent fixing of the stator shape is implanted curable resin while maintaining the shape pay the mold to Tapisu, characterized in that it comprises a city.

[0007] According to this configuration, it becomes possible to obtain a split stator core having a highly rigid core and a welded portion in the welding step, and to obtain a high space factor by winding while processing the square wire in the coil winding step. Can easily be obtained, and the performance of the wheel-in motor can be improved. In addition, it is possible to obtain a compact divided stator piece having a predetermined shape by eliminating swelling of the coil in the coil forming step, and in the stator combining step, the wiring step, and the molding step,
A predetermined thin and compact stator can be obtained, and a thin and compact stator for a wheel-in motor can be easily manufactured. Therefore, it is possible to make the wheel-in motor thinner and more compact.

According to a second aspect of the present invention, in the first aspect, the welding step is a two-stage welding in which, after performing low-power welding, high-power welding is performed at the same position. There is a feature.

According to this configuration, the gas generated from the insulating film of the laminated electromagnetic steel sheets is eliminated by the heat generated during the low-power welding, so that the bubbles are not left at the welding portion, and thereafter, the gas is applied to the same position. By the high-power welding, it is possible to form a more rigid welding layer without bubbles.

According to a third aspect of the present invention, in the first or second aspect, the welding step comprises laminating a predetermined number of electromagnetic steel sheets sequentially punched and formed by a punch press inside the die. After that, the punch enters the inside of the die, and welding is performed in a state where the laminated electromagnetic steel plates are pressed against each other at a predetermined pressure.

[0011] According to this configuration, the arrangement of the punched electromagnetic steel sheets can be adjusted using the internal shape of the die, and the entire surface of the electromagnetic steel sheets can be pressed against the entire surface of the electromagnetic steel sheet with a punch at a uniform high pressure. Since welding becomes possible, punching, laminating, and welding operations of electromagnetic steel sheets can be efficiently performed in a series of operations. Therefore, a split stator core can be manufactured.

According to a fourth aspect of the present invention, in the first aspect of the present invention, the coil winding step includes the step of winding the small diameter portions of two stepped rollers having a small diameter portion and a large diameter portion. Are wound around the divided stator core by passing a round wire in a substantially rectangular space having a substantially rectangular cross section formed by facing each other in the radial direction and facing the large-diameter portions in a direction perpendicular to the radius.

According to this configuration, the round wire having the insulating film uniformly formed on the surface thereof is passed through the substantially rectangular space in cross section formed by the two rollers to form the square wire having the insulating film having a uniform edge portion. It can be easily formed with a simple configuration. Further, by using the square wire, the square wire can be wound around the divided stator cores at high density.

According to a fifth aspect of the present invention, in the fourth aspect of the present invention, the molded square wire is further formed by a stepped roller having at least one of the small diameter portions of the stepped roller tapered. A square wire processed through the formed flat cross-sectional shape space is wound around the split stator core.

According to this configuration, when the divided stator pieces are combined in an annular shape, the outer shape of the coil can be tapered so that adjacent coils do not interfere with each other. An even higher space factor can be easily obtained. In addition, since the swelling of the surface of the coil can be eliminated, a compact split stator piece can be formed, and the stator can be made compact and thin. If a stepped roller having a taper is selectively used when forming a square wire, the cross-sectional shape of one square wire can be partially changed. In this case, the square wire includes a wire having a trapezoidal or triangular cross section.

In order to achieve the above object, according to a sixth aspect based on the first aspect, the coil winding step comprises four mutually contactable and separable circumferential surfaces arranged so as to be orthogonal to each other. The method is characterized in that a square wire processed by passing a round wire through a substantially rectangular space formed by a roller is wound around the divided stator core.

According to this configuration, the size of the square wire can be easily changed when the square wire is processed from the round wire, and it is possible to easily cope with various models.

According to a seventh aspect of the present invention, in the sixth aspect of the present invention, at least one of the four rollers is inclined, and a flat sectional space formed by the four rollers is provided. And winding the square wire rod processed through the split stator core.

According to this configuration, square wires having various cross-sectional shapes can be easily produced by tilting an arbitrary roller in the axial direction. In addition, it is possible to easily form a square wire having a partially different cross-sectional shape during a series of press working.

In order to achieve the above object, according to an eighth aspect based on the first aspect, the coil winding step includes, when the square wire is wound around the divided stator core, a corner of the divided stator core. The corner wire portion corresponding to the portion is bent in advance according to the shape of the corner portion.

Here, the square wire is sandwiched between a pair of dies (upper and lower dies) and bent in advance according to the outer shape of the divided stator core. However, when the dies are opened, they return slightly by springback, so that the desired bending angle is obtained. It is preferable to bend a few degrees more. According to this configuration, the rectangular wire can be wound in close contact with the shape of the divided stator core, so that the rectangular wire can be prevented from bulging and a compact stator can be manufactured.

According to a ninth aspect of the present invention, in the first aspect of the present invention, the coil winding step includes the steps of: winding the square wire from the nth layer to the (n + 1) th layer; The winding position is moved while winding the square wire along a guide that abuts on the n-th layer and crosses obliquely to the winding direction of the n-th layer.

Here, the guide member is formed of a resin or the like so as not to damage the insulating coating of the square wire. According to this configuration, even when the winding position of the rigid square wire greatly changes, it is possible to accurately guide the square wire to the predetermined winding position, thereby improving the space factor and expanding the square wire. Lifting can be prevented, and a compact stator can be manufactured.

In order to achieve the above object, the tenth aspect
According to a first aspect of the present invention, in the first aspect, the coil forming step presses the divided stator pieces into a predetermined shape while supporting the laminated electromagnetic steel sheets from both sides with support blocks and maintaining the laminated arrangement. And

According to this configuration, even when the split stator pieces are pressed at a high pressure to shape the coil portion, the laminated state of the electromagnetic steel sheets is not broken, so that a compact stator with a uniform shape is manufactured. can do.

Further, in order to achieve the above object, an eleventh
In the invention according to the first aspect, the connection step includes:
After crimping the coils in a state where the ends of the coils are raised from the coil winding surface, the crimping portion is inserted into an empty space of the wound coil.

According to this configuration, a sufficient crimping work area can be secured by raising the end of the coil from the coil winding surface, so that the connection work of each coil can be performed quickly and easily. it can. Further, by inserting the crimped portion into the empty space of the wound coil, the space can be effectively used, and a compact stator can be manufactured.

Further, in order to achieve the above object, a twelfth
In the first invention, in the first invention, the molding step uses a mold that combines a plurality of separable mold pieces, and removing the stator from the mold after hardening the resin includes screwing a bolt into the mold piece. It is performed by the urging force of the bolt against the stator at the time.

According to this configuration, a plurality of mold pieces hold the shape corresponding to the shape of the stator to enable complete injection of the molding resin, and the mold pieces can be divided into a plurality of pieces, so that the stator can be quickly and easily formed. , And the assemblability of the stator is improved.

[0030]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention (hereinafter referred to as embodiments) will be described below with reference to the drawings.

FIG. 1 is a schematic view of a wheel-in motor 10 produced by the manufacturing method of the present embodiment. The wheel-in motor 10 according to the present embodiment includes a plurality of divided stator pieces 12 each having a coil 12a around a tooth.
After connecting the coils in a ring shape and connecting each coil,
The outer rotor 16 is attached to the periphery of the vehicle, which is permanently fixed with the mold resin 14, and the wheel-in motor 10 is completed.

FIG. 2 is a flowchart showing a procedure for manufacturing the wheel-in motor 10. First, in a welding step (welding step; S100) of forming a core of a split stator, a plurality of electromagnetic steel sheets sequentially punched into a predetermined shape by a punch press or the like are stacked, then welded and connected to each other to form at least one tooth. Is formed. Subsequently, a wire is wound around the split stator core to form a coil, thereby forming a split stator piece (coil winding step; S101). The wire material wound at this time is pressed into a rectangular wire having a substantially rectangular cross section by a press roller in the process of unwinding a round wire having a substantially circular cross section from a bobbin and winding the same around the divided stator core. By using the square wire, the wire material can be wound around the split stator core at a high density (high space factor), and the performance of the wheel-in motor 10 can be improved. In addition, the wire material for the coil has an insulating coating on the surface, but in the case of a round wire, since the insulating coating is formed uniformly over the entire circumference, the round wire is formed into a square wire by a press roller. However, the insulating coating is evenly formed on the entire circumference of the square wire, and high insulation can be maintained. In other words, when an insulating coating is formed after forming a square wire from a material, the insulation coating on the edge portion of the square wire is poorly applied and the insulation is reduced, and the insulation strength is reduced. In the case of press working at the time of drawing, a partial difference in the thickness of the insulating film is reduced, so that a sufficient insulating strength can be secured while improving the space factor.

Normally, when a square wire is wound around a core, the wound square wire swells out of a desired winding shape due to springback due to the rigidity of the square wire. Therefore, in the present embodiment, there is provided a coil forming step (S102) in which the swollen portion of the square wire is uniformly pressed from both sides to form a coil having a predetermined shape. By providing the coil forming step, the workability at the time of the stator assembling step (S103) for assembling the divided stator pieces 12 in a ring shape is improved, and it is not necessary to prepare an extra space for the bulging of the coil. 10 can be made compact.

Subsequently, the related coil terminals are connected to the ring-shaped divided stator pieces 12 using crimp terminals or the like (connection crimping; S104). At this time, if crimping is performed with the ends of the coils raised from the coil winding surface, a crimping work area can be easily secured, and the crimping work can be performed easily and quickly. Further, by inserting the crimp portion including the crimp terminal into the empty space formed by the arrangement of the wound square wires, the space can be effectively used, and the stator can be made compact.

The divided stator pieces 12 assembled in a ring shape and having completed the connection of the coils are placed in a mold for permanent maintenance of the assembled shape, and fixed with a mold resin (S105). After this, when taken out of the mold, the stator of the wheel-in motor 10 is
Complete. Then, the outer rotor is mounted on the outer peripheral portion of the stator (S106), and a resolver for detecting the amount of rotation (rotational position) of the outer rotor is assembled (S107) to complete the wheel-in motor 10.

Hereinafter, specific operations in each step will be described in detail.

FIGS. 3 and 4 are explanatory views for explaining a method of laminating and welding the electromagnetic steel sheets 18 in the welding step (S100). As shown in FIG. 3, the electromagnetic steel sheet 18 has teeth 18a on which a square wire is actually wound. The electromagnetic steel sheets 18 are punched one by one by a punch press or the like, and as shown in FIG. 3, are brought into close contact with the guide grooves 20a and the slopes 20b of the alignment block 20 (both conform to the shape of the laminated steel sheets 18). Are sequentially inserted. When the predetermined number of electromagnetic steel plates 18 have been inserted, the pressing block 22 is fixed to the alignment block 20 with bolts 24. At this time,
The protruding portion 22a of the pressing block 22 is
Are pressed against each other. Further, the aligning block 20 to which the pressing block 22 is fixed is fixed to the tightening block 2.
Fit into 6. A guide key 26 a is formed in the tightening block 26, and can be engaged with a key groove 20 c formed in the alignment block 20. Therefore, the alignment block 20 can be fixed in position with respect to the tightening block 26. In this state, a large-diameter bolt 28 that can be screwed into the tightening block 26 and that can pass through the opening 22b of the pressing block 22 and directly contact the electromagnetic steel plate 18 is tightened with a tightening limit torque. As a result, the electromagnetic steel sheet 18 can be further pressed in the stacking direction. By this pressing, the burrs formed at the time of punching out the electromagnetic steel sheets 18 can be completely crushed, and the respective electromagnetic steel sheets 18 can be brought into close contact. Then, if the bolt 24 is tightened in the state of being tightened by the large-diameter bolt 28, the pressure contact can be maintained by the pressing block 22. As described above, by performing the two-stage tightening using the large-diameter bolt 28, a strong pressure welding can be easily performed.

The alignment block 2 removed from the tightening block 26 in a state where the pressing by the pressing block 22 has been performed.
0 is fixed to the turntable 30 as shown in FIG. The connection between the alignment block 20 and the rotary table 30 is as follows.
The keyway 20c and the guide key 3 on the rotary table 30
0a. In this state, the CO ₂ laser welding head 32 is brought closer to the lamination surface (the upper surface in FIG. 1) of the laminated electromagnetic steel sheets 18. The electromagnetic steel sheet 18 contains Si in order to reduce iron loss, and has an insulating film formed on the surface. Therefore, gas is generated from the insulating film portion by heating during welding. Conventionally, the generated gas is easily released by lowering the degree of adhesion of the electromagnetic steel sheet 18. However, the rigidity of the welded part is reduced to cause welding cracks, and the lamination of the electromagnetic steel sheet 18 is broken. Had. In the case of the present embodiment, since the burrs are crushed by pressing with high pressure to improve the degree of adhesion, the rigidity of the divided stator core itself can be improved. On the other hand, the gas may not completely escape and bubbles may be formed in the weld layer. Therefore, in this embodiment, a low output, for example, 100 W
Hereinafter, the first welding along the lamination direction of the electromagnetic steel sheets 18 is performed. The feed speed of the welding head 32 at this time is 200
A value of about mm / min is appropriate. By performing welding at a low output and at a low speed, it is possible to sufficiently burn off the Si of the electromagnetic steel sheet 18 and the insulating layer, and it is possible to prevent the formation and retention of bubbles. After that, the same position is
By performing welding (two-step welding) again with a high output of about W, high-rigidity welding with a width of 0.8 mm and a depth of 0.6 mm can be performed, for example.

Thereafter, the rotary table 30 is set at 180 °
By rotating, the two-stage welding of the lower surface side of the electromagnetic steel plate 18 is performed. In addition, when the rotary table 30 is rotated by 180 °, the lowering position of the CO ₂ laser welding head 32 is
It is desirable to connect the alignment block 20 and the rotary table 30 so that the upper surface position and the lower surface position of the electromagnetic steel plate 18 are at the same height. By performing such a setting, quick double-sided welding can be performed without fixing and correcting the alignment block 20. The alignment block 20
Since the connection between the rotary table 30 and the rotary table 30 requires only the accuracy of the chuck position and does not require a large chuck strength,
A chuck mechanism using a cylinder, a magnet, or the like may be used.

FIG. 5 shows another method of manufacturing the split stator core. As shown in FIG. 5, the electromagnetic steel sheet 18 is made of a material 3 by a punch 34 and a die 36 of a punch press.
Punched one after another. At this time, as shown in FIG. 5, the punched electromagnetic steel sheets 18 are sequentially dropped into a die 36 and laminated. After the predetermined number of electromagnetic steel sheets 18 have been stacked, the punch 34 is advanced into the die 36 and the punch 3
The laminated electromagnetic steel sheets 18 are pressed against each other by using the pressing force of No. 4, and the burrs of the electromagnetic steel sheets 18 generated at the time of punching are crushed.
Then, the die 3 is pressed in a state of being pressed by the punch 34.
Welding window 36a formed on the side of No. 6 (only one side is shown)
, The CO ₂ laser welding head 32 is brought into contact with the laminated electromagnetic steel sheet 18 to perform two-stage welding in the same manner as described above. In addition, on the lower surface of the die 36, an openable and closable lid having a strength that can withstand the pressure contact of the punch 34 is arranged, and the split stator core after welding is discharged to the outside of the die 36 by opening the lid.

As described above, when the electromagnetic steel sheet 18 is pressed and welded at the time of punching, the split stator core can be manufactured more quickly. In the case where pressure welding and welding are performed using the die 36, the die 36 and the electromagnetic steel plate 18 are used.
Copper chips 36b for heat dissipation are arranged above and below the welding window 36a so as to prevent welding.

FIG. 6 shows the completed split stator core 40.
(The square wire is not yet wound) is arranged in a ring shape, and the outer rotor 4 having a permanent magnet 42 around the outer rotor 4.
4 shows a state in which 4 is arranged. When the wheel-in motor actually rotates, each split stator core 40 attracts the permanent magnet 42, so that a force acts in the direction of arrow A in FIG. For this reason, as shown in FIG.
6 and pawls 40a and 40b that can be engaged with each other. The force in the direction of the arrow A is canceled by the parallel pin 46, and the force in the direction of the arrow B is canceled by engaging the claws 40a and 40b. By providing such parallel pins 46 and claws 40a and 40b, the connection of the split stator cores (split stator pieces) is maintained, the assembly is facilitated, and the manufacture of the stator is simplified.

FIG. 8 is a sectional view showing a state in which the square wire 48 is wound around the split stator core 40. As described above, it is preferable to improve the space factor of the coil of the stator in order to reduce heat loss due to coil resistance. Therefore, it is better to wind a square wire having a rectangular cross section than an electric wire having a circular cross section.

In this embodiment, as described above, in order to make the thickness of the insulating coating on the surface of the square wire 48 equal to that of the flat portion at the edge of the square wire 48, the insulating coating is formed evenly over the entire circumference. The round wire thus formed is crushed by a press roller to form a square wire, and the insulating coating having the same thickness as the flat portion is maintained even at the edge portion, thereby preventing a decrease in insulation performance.

FIG. 9 shows that the square wire 48 is formed from the round wire 52 wound on the bobbin 50 and the divided stator core 4 is formed.
A conceptual diagram of a winding device 54 that winds around zero is shown. The winding device 54 has a press roller 56 for pressing the round wire 52 into the square wire 48 at a position adjacent to the bobbin 50, and is attached to the downstream side when the round wire 52 is wound around the bobbin 50. It has straightening rollers 58a to 58c (three in the present embodiment) for correcting the curl in the reverse direction. Further, on the downstream side, a chuck 60 that supports the split stator core 40, is rotatable in the winding direction of the square wire 48, and is movable in the radial direction of the split stator core 40 (perpendicular to the paper surface) is arranged.

The press roller 56 is shown in FIG.
As shown in (b), it is composed of two stepped rollers having a small diameter portion 56a and a large diameter portion 56b. As shown in FIG. 10B, each stepped roller faces the small-diameter portions 56a in the radial direction and the large-diameter portions 56b in the direction perpendicular to the radius (the direction along the rotation axis 64). The round wire 52 is processed into a square wire 48 by passing the round wire 52 through a substantially rectangular space 62 having a substantially rectangular cross section. The processed square wire 48 is removed from its curl by the correction rollers 58a to 58c, and is wound around a predetermined position of the divided stator core 40 that moves in the radial direction while rotating by a motor (not shown). The contact surface where the press roller 56 contacts the round wire 52 is mirror-finished, and the edge portion is also R-processed so that the insulating coating of the square wire 48 is not damaged.
Further, the press roller 56 is rotatably supported by a bearing 66, and the bearing 66 is an eccentric inner ring shaft 68.
, And the inner ring shaft 68 is supported by the frame 70. Therefore, by rotating the inner ring shaft 68, the relative position of the bearing 66, that is, the relative position of the press roller 56 can be adjusted, and the vertical direction in the drawing of the substantially rectangular section 62 can be adjusted. Can be easily changed.

As described above, the round wire 52 having the insulating film uniformly formed on the surface thereof is passed through the substantially rectangular space 62 having a cross section formed by the two press rollers 56 so that the edge portion has a uniform insulating film. The wire 48 can be easily formed with a simple configuration. Moreover, since the curling of the square wire 48 is eliminated by the straightening rollers 58a to 58c, the swelling due to springback can be reduced even when the straight wire is wound around the divided stator core 40. It is also conceivable to press the round wire 52 into the square wire 48 in a separate step. In this case, however, it is necessary to wind the square wire 48 around the bobbin again for storage and transportation, and the insulation coating on the surface of the square wire 48 Since there is a risk of damaging the components and the like, by winding the stator core 40 immediately after the press working as in the present embodiment, the quality can be improved and the productivity can be improved. Further, by using the square wire 48 thus pressed, the square wire 48 can be wound around the divided stator cores 40 at high density.

As shown in FIG. 8, the split stator core 40 has a substantially sector shape, and therefore, it is desirable that a part of the square wire 48 at the outer peripheral portion has a substantially trapezoidal cross section. This trapezoidal shape is formed in a coil forming step (S102).
Although it is possible to shape the wire material, it is desirable to press the wire material in two stages as shown in FIG. In the case of FIG. 11A, first, the round wire 52 is squared by the press roller 56 into the square wire 48.
Process into Then, the flat wire 4 is applied to the square wire 4 by the flat press roller 72.
8 is further pressed to obtain a flat wire 74 having a substantially trapezoidal cross section.
Process into The flat press roller 72 is shown in FIG.
As shown in FIG. 10, it has almost the same configuration as the press roller 56 shown in FIG. 10A, but the small diameter portion 72a of the press roller has a taper, and the space formed by the two press rollers Is a flat sectional shape space 76 (FIG. 11B).
In this case, a substantially trapezoidal cross section is formed. When winding the coil around the divided stator core 40, first, a rectangular wire 48 having a rectangular cross section is wound, and a flat wire 74 having a substantially trapezoidal cross section only at the outer peripheral portion is wound. Therefore, the frame 78 that supports the flat press roller 72 and the like has an actuator that drives the flat press roller 72 to move in the vertical direction in FIG. 11B, and the square wire 48 is selectively provided only in the portion where the flat wire 74 is required. Is to be pressed.
Note that the embodiment shown in FIG. 11A shows a case where the flat press roller 72 is shared as a correction roller.

As described above, by using the flat wire member 74, it is possible to prevent adjacent coils from interfering with each other when the divided stator pieces 40 are combined in an annular shape. Further, a higher space factor can be easily obtained. Further, a compact split stator piece can be formed, and the stator can be made compact and thin. In addition, if the taper angle of the small diameter portion 72a is appropriately selected, it is possible to easily cope with various models. FIG. 11B shows a case where the cross section of the formed electric wire material has a trapezoidal shape, but a triangular shape can also be processed.

FIG. 12 shows a configuration in which the square wire 48 or the flat wire 74 is pressed from the round wire 52 by another configuration. In the case of this configuration, the four press rollers 80a to 80d have their peripheral surfaces orthogonal to each other,
And the four press rollers 8
The round wire 52 is pressed in the space defined by 0a to 80d. When the four press rollers 80a to 80d are arranged so that their peripheral surfaces are orthogonal to each other, the round wire 52 is a rectangular wire 48 having a rectangular cross section as shown in the example of FIG.
become. Further, as shown in FIG.
If at least one of a to 80d is adjusted to be inclined with respect to the passing direction of the round wire 52 (in FIG. 12, the press rollers 80c and 80d are inclined at angles α and β),
The flat wire 74 having a substantially trapezoidal cross section can be directly pressed from the round wire 52.

As is apparent from FIG. 8, when the coil is wound around the split stator core, the shape of the flat wire slightly differs depending on the winding position. Press rollers 80a-80 of FIG.
In the case of 80d, the press roller 80c,
Since the inclination angle such as 80d can be changed, it is possible to quickly follow even a slight shape change of the flat wire 74,
It can contribute to the improvement of the space factor. Further, since the entire shape of the coil can be made a desired shape, it can contribute to downsizing of the stator to be manufactured.
The structure around the shaft of the press rollers 80a to 80d is as follows.
It is the same as FIG.
0d on the side of the frame supporting the press rollers 80a to 80d.
An inclining mechanism or the like for inclining 80d is arranged.

When the coil is wound by a winding device as shown in FIGS. 9 and 11A, if the winding is to be performed only by the tension of the square wire 48, the square wire 48 and the flat wire 74 tend to swell without being fully bent. Therefore, FIG.
As shown in (c), it is desirable to bend the square wire 48 in accordance with the shape of the teeth edge by using the upper mold 82 having a convex portion and the lower mold 84 having a concave portion. The radius of the R portion 82a of the convex portion of the upper mold 82 is, for example, a round wire 48
Is the minimum bending radius (radius of wire section) of the lower die 8
It is preferable that the radius of the R portion 84 a of the concave portion of the fourth is equal to, for example, the minimum bending radius of the round wire 48 + the cross-sectional diameter of the round wire 48. The edge portion of the tooth is approximately 90 °, but there is a bending back due to the spring back of the square wire 48. Therefore, for example, if the bending angle by the upper mold 82 and the lower mold 84 is set to about 85 °, it is desired at the time of bending return. 90 ° of
Is obtained.

FIG. 14 shows an upper die 8 attached to the winding device 54 described above.
This is an example in which a bending mechanism using the second and lower dies 84 is mounted. The upper die 82 and the lower die 84 are fixed to a driving means such as a direct-acting cylinder 86 at a position immediately before the chuck 60, and bend the square wire 48 at a predetermined timing by the operations shown in FIGS. In this manner, by bending the square wire 48, the square wire 48 can be wound in close contact with the shape of the divided stator core 40, so that the square wire 48 can be prevented from bulging and a compact stator can be provided. Can be manufactured. Note that, in the case of FIG.
Unlike the other examples, the correction roller 58c presses the upper side of the passage of the square wire 48, but this is because
This is to prevent the square wire 48 from jumping up when bending by the upper mold 82 and the lower mold 84.

FIG. 15 shows an arrangement of insulating means for preventing the insulation coating of the square wire 48 from being broken at the edge of the split stator core 40 before winding the square wire 48 around the split stator core 40. Is explained. A resin insulating plate 88 having a high insulating property is arranged on both end surfaces of the laminated electromagnetic steel sheets 18, and an insulating paper 90 bent in a U-shape is arranged in the teeth portion. The insulating plate 88 is slightly (for example, about 0.25 mm) from the lamination surface of the divided stator cores 40 as shown in FIG.
The end of the insulating paper 90 and the insulating plate 8
8 partially overlaps. By arranging the insulating paper 90 and the insulating plate 88 in this manner, when the square wire 48 is wound, the square wire 48 and the divided stator core 4
Even when an excessive external force acts on the square wire member 0, reliable insulation between the square wire 48 and the divided stator cores 40 can be maintained.

FIGS. 17A and 17B show a method of treating the insulating paper 90 after the winding of the square wire 48 is completed. The end portion 90a of the insulating paper 90 protruding from the square wire 48 is formed as shown in FIG.
As shown in FIG. 7 (b), it is folded so as to partially overlap. At this time, it is desirable that the overlapping portion comes to an empty space formed by winding the square wire 48. In this manner, by folding the simple shape of the insulating paper 90 formed in a U-shape and arranging it inside and outside the coil, complete insulation can be performed while protecting the insulating coating. In the example of FIG. 17A, the configuration is described in which both ends of the insulating paper 90 protrude. However, only one side is protruded so that only one side is folded to cover the entire surface of the coil and no overlapping portion is formed. By doing so, the swelling due to the overlap can be eliminated and the stator can be made compact.

FIG. 18 shows a configuration for efficiently and accurately winding the square wire 48 when the square wire 48 is wound around the divided stator core 40 held by the rotatable chuck 60. ing. When winding the square wire 48 around the divided stator core 40, when winding the same layer in an array,
Since the winding pitch is small (wire diameter pitch), adjustment of the feeding position of the square wire 48 and pitch feed of the chuck 60 (FIG. 1)
8 (a) in the vertical direction). However, for example, when the winding of the second layer is completed and the winding of the third layer is started, the square wire 48 is divided into the divided stator cores 4.
Therefore, it is necessary to move obliquely from the root side of the zero to the tip side. Since the square wire 48 used in the present embodiment has a round wire diameter of about 2.5 to 3.0 mm, the rigidity of the square wire 48 is increased, and the square wire 48 can be accurately wound with a normal winding torque. It becomes difficult to wrap around. Therefore, at the time of interlayer movement of the square wire 48 (from the nth layer to the (n + 1) th layer),
A guide block 92 having a slope 92a is selectively brought into contact with a winding surface (n-th layer) by an actuator (not shown) along an oblique winding path as shown in FIG. At the time of winding, the square wire 48 is connected to the slope 92a.
By sliding upward, even when the square wire 48 crosses obliquely, it can be guided to an accurate winding position. Note that the guide block 92 is desirably formed of resin so as not to damage the insulating coating of the square wire 48. Further, the guide block 92 is hooked on a part of the divided stator core 40 and the chuck 60 so that the hook 92b does not shift during winding.

Incidentally, the wound square wire 48 is swollen from a predetermined shape only by the winding operation. Also,
Even when a flat wire is wound around the outer periphery, it is difficult to completely obtain a desired coil shape because of winding deviation and the like.
Therefore, in this embodiment, the final shaping is performed after the coil is wound. FIG. 19 shows a press block that is used to wind the coil into a desired shape after winding the square wire 48 around the split stator core 40. The split stator piece 12 for which the winding of the coil has been completed is placed on the holding block 96, and a high pressure (7-1)
0t). The holding block 96 has a function of protecting a portion other than the coil of the split stator piece 12 from being subjected to pressure during a pressing operation by the pressing block 98.

As shown in FIG. 20, in the above-described split stator core 40, the welded portion 100 of the electromagnetic steel sheet 18 in the laminated state sandwiched between the insulating plates 88 is provided with the split stator core 40 to reduce overcurrent loss. It is located in a narrow range only at the center of the upper and lower surfaces. Therefore, when pressing is performed by the press block 98 as described above, the electromagnetic steel sheets 18 may be displaced from each other to form a rhombus as shown in the lower part, and the split stator pieces 12 may be broken. Therefore, as shown in FIG. 19, a pair of support blocks 102 engageable with the holding block 96,
The electromagnetic steel sheet 18 is supported in the stacking direction. The support block 102 is driven by a pressing device (not shown) to maintain the arrangement so that the lamination of the electromagnetic steel sheets 18 in the holding block 96 does not collapse. Therefore, the split stator piece 12 does not lose its shape even when the coil portion is pressed at a high pressure by the press surface 98a of the press block 98.

Thus, the manufacture of the split stator piece 12 is completed. Next, as shown in FIGS. 6 and 7, the split stator pieces 12 are arranged in a ring by combining the claws 40a and 40b formed on the split stator core 40 (FIG. 6 shows an array of only the split stator cores). . When the divided stator pieces 12 are arranged in a ring shape, it is necessary to electrically connect the associated coils. Therefore, the coil terminals of the divided stator pieces 12 are
Stand up perpendicular to the array direction. Then, as shown in FIG. 21, each coil terminal 104 is pulled in an arch shape and connected by a crimp terminal 106. As shown in FIG. 22 (a), the connection of the crimp terminal 106 is performed by first connecting the coil terminal 10
4 is raised perpendicularly to the arrangement direction of the electromagnetic steel plates 18, and then the related coil terminals 104 are pulled together to form the crimp terminals 10
Connect with 6. The crimping device 108 is used for the connection.
The crimp terminal 106 used for this connection is shown in FIG.
As shown in (1), it is dropped into the empty space formed by the wound coil, and the mold 110 is finally applied so that the crimped portion does not protrude from the coil end. A power line 112 for driving the coil
Is spirally passed through a hole formed in a structure 114 disposed inside the stator, connected to the coil side by a crimp terminal 116, and formed by a coil wound in the same manner as the crimp terminal 106 described above. Fallen into the empty space. The power line 112 is housed in a spiral groove 114 a formed in the structure 114 and is molded so as not to protrude from the structure 114.

After the coil terminals 104 are set up vertically in the direction in which the magnetic steel sheets 18 are arranged, the crimp terminals 106
By connecting them to each other and dropping them into an empty space, connection crimping work can be performed easily, and the coil end can be made compact, contributing to downsizing and thinning of the stator and wheel-in motor. be able to.

The finally assembled split stator piece 12
Permanently fix its shape as a stator. FIG.
As shown in (a) and (b), a plurality of mold pieces (a ring, an inner lid, an upper lid, a bottom plate, an upper plate, etc., which will be described later) surround the stator, and the molding resin is injected and cured. That is, the assembled stator is housed in the ring 118, the inner cover 120 is inserted inside the stator, the bottom plate 124 in which the jig 122 is housed, and the upper cover 126 are attached.
24 and the upper lid 126 are tightened and fixed. Thereafter, the bottom plate 124 and the ring 118 are fixed by the bolt 130. Further, the upper plate 132 is mounted and fixed to the ring 118 with bolts 134. Then, the softened mold resin is poured into the assembled stator from the injection port 132a formed in the upper plate 132, and the entire mold piece is put into a drying furnace or the like to cure the mold resin.

After the molding resin is cured, first, the bolt 130 is removed, and the screw hole 1 formed in the upper plate 132 is removed.
Screw the extraction bolt into 32b. As a result, the upper plate 13
2 and the ring 118 can be moved straight in the axial direction of the extraction bolt to be extracted from the stator. Subsequently, the bolt 128 is removed, and the screw hole 12 formed in the bottom plate 124 is removed.
When the extraction bolt is screwed into 4a, the bottom plate 124 moves straight in the axial direction of the extraction bolt and can be extracted from the stator. Finally, if the inner lid 120 and the upper lid 126 are removed, all the mold pieces are released, and a stator in which the combined split stator pieces are permanently fixed is completed.

As described above, a complete resin injection becomes possible by holding a plurality of mold pieces corresponding to the shape of the stator. Further, the mold piece can be quickly and easily separated from the stator, and the assemblability of the stator is improved.

The completed stator is as shown in FIG.
The outer rotor is mounted around the outer rotor, and a resolver or the like for detecting the rotation angle of the outer rotor is fixed, thereby completing the wheel-in motor. Further, the wheel-in motor is covered with an aluminum wheel or the like, and tires are mounted around the outer rotor, thereby completing a driving wheel of an automobile.

[0065]

According to the present invention, a thin, compact, high-performance wheel-in motor stator can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram of a wheel-in motor using a stator formed by a manufacturing method according to an embodiment of the present invention.

FIG. 2 is a flowchart illustrating a method for manufacturing a stator of a wheel-in motor according to an embodiment of the present invention.

FIG. 3 is an explanatory diagram for explaining the pressing operation of the electromagnetic steel plate in the welding step of the manufacturing method according to the embodiment of the present invention.

FIG. 4 is an explanatory view illustrating a welding operation in a welding step of the manufacturing method according to the embodiment of the present invention.

FIG. 5 is an explanatory diagram illustrating another press-welding and welding operation of the welding step of the manufacturing method according to the embodiment of the present invention.

FIG. 6 is an explanatory diagram illustrating a state where split stator cores manufactured by the manufacturing method according to the embodiment of the present invention are assembled.

FIG. 7 is an explanatory diagram illustrating a combined structure of split stator cores manufactured by the manufacturing method according to the embodiment of the present invention.

FIG. 8 is an explanatory diagram illustrating a winding state of a square wire wound around a split stator core manufactured by the manufacturing method according to the embodiment of the present invention.

FIG. 9 is a schematic view of a winding device that is a device used in a coil winding step of the manufacturing method according to the embodiment of the present invention and that performs coil winding on a divided stator core while pressing a round wire into a square wire.

FIG. 10 is an explanatory diagram illustrating a configuration of a press roller used in the winding device illustrated in FIG. 9;

FIG. 11 shows an apparatus used in the coil winding step of the manufacturing method according to the embodiment of the present invention, in which a coil is wound around a split stator core while continuously pressing a round wire into a square wire and a flat wire. It is the schematic of an apparatus.

FIG. 12 is an explanatory diagram illustrating an apparatus used in a coil winding step of the manufacturing method according to the embodiment of the present invention, which is a press roller for pressing a round wire into a square wire or a flat wire.

FIG. 13 is an explanatory view illustrating an apparatus used in the coil winding step of the manufacturing method according to the embodiment of the present invention, and illustrating a method of bending a square wire prior to coil winding.

14 shows a bending mechanism based on the bending method of FIG. 13 in FIG.
FIG. 4 is a conceptual configuration diagram when applied to the winding device of FIG.

FIG. 15 is an explanatory diagram illustrating mounting of an insulating plate and insulating paper used for a split stator core used in the manufacturing method according to the embodiment of the present invention.

FIG. 16 is an explanatory diagram for explaining a mounting state of an insulating plate and insulating paper used for a split stator core used in the manufacturing method according to the embodiment of the present invention.

FIG. 17 is an explanatory diagram illustrating a state in which an insulating plate and insulating paper are mounted on a split stator core used in the manufacturing method according to the embodiment of the present invention and a coil is wound.

FIG. 18 is an explanatory diagram for explaining interlayer movement winding of the square wire in the coil winding step of the manufacturing method according to the embodiment of the present invention.

FIG. 19 is an explanatory diagram illustrating a shaping procedure in a coil forming step of the manufacturing method according to the embodiment of the present invention.

FIG. 20 is an explanatory diagram illustrating a possible misalignment of an electromagnetic steel sheet in a coil forming step.

FIG. 21 is an explanatory diagram illustrating a stator combination step and a connection step of the manufacturing method according to the embodiment of the present invention.

FIG. 22 is an explanatory diagram illustrating a connection step of the manufacturing method according to the embodiment of the present invention.

FIG. 23 is an explanatory diagram illustrating a molding step of the manufacturing method according to the embodiment of the present invention.

[Explanation of symbols]

10 Wheel-in motor, 12 split stator pieces, 12a coil, 14 molded resin, 16 outer rotor.

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3D035 DA03 5H615 AA01 BB01 BB14 PP01 PP10 PP14 PP15 QQ02 QQ19 QQ27 SS03 SS04 SS05 SS13 SS15 SS17 SS20 SS44 TT04 TT05 TT26

Claims (12)

[Claims] 1. A method of manufacturing a stator for a wheel-in motor, comprising: welding a plurality of electromagnetic steel plates while pressing the plurality of electromagnetic steel plates together to form a split stator core having at least one tooth; A coil winding step of forming a divided stator piece by winding the divided stator core while processing the coil into a square wire, and forming a coil into a predetermined shape by uniformly pressing the swollen portion of the coil of the divided stator piece from both sides. A stator assembly step of combining the divided stator pieces into a ring shape; a wiring step of connecting the associated coil terminals of the divided stator pieces combined in a ring shape; and each of the ring combinations combined in a ring shape With the stator piece placed in the mold and maintaining its shape, A mold step of injecting and permanently fixing the stator shape, and a method of manufacturing a wheel-in motor stator. 2. The method according to claim 1, wherein the welding step includes performing low-power welding and then performing high-power welding at the same position.
A method for manufacturing a stator of a wheel-in motor, which is step welding. 3. The method according to claim 1, wherein the welding step includes laminating a predetermined number of magnetic steel sheets sequentially punched and formed by a punch press in the die, and then moving the punch into the die. A method for manufacturing a stator of a wheel-in motor, wherein welding is performed in a state where the laminated electromagnetic steel plates are pressed against each other at a predetermined pressure. 4. The method according to claim 1, wherein the step of winding the coil includes the step of making the small-diameter portions of two stepped rollers having a small-diameter portion and a large-diameter portion face each other in a radial direction and making the large-diameter portions have a radius. A rectangular wire formed by passing a round wire through a substantially rectangular space having a substantially rectangular cross section formed so as to face in a direction perpendicular to the stator. 5. The method according to claim 4, wherein the formed square wire is further processed through a flat sectional shape space formed by a stepped roller having a tapered small-diameter portion of at least one of the stepped rollers. A method for manufacturing a stator of a wheel-in motor, comprising: winding a wire around the split stator core. 6. The method as claimed in claim 1, wherein the coil winding step comprises:
A method of manufacturing a stator for a wheel-in motor, comprising: winding a square wire processed by passing a round wire through a substantially rectangular space formed by a plurality of rollers around the divided stator core. 7. The method according to claim 6, wherein at least one of the four rollers is inclined, and a square wire processed through a flat cross-sectional space formed by the four rollers is wound around the split stator core. A method for manufacturing a wheel-in motor stator, comprising: rotating the stator. 8. The method according to claim 1, wherein, in the step of winding the coil, when the square wire is wound around the split stator core, the square wire portion corresponding to a corner portion of the split stator core is pre-angled. A method for manufacturing a stator of a wheel-in motor, wherein the stator is bent according to the shape of a portion. 9. The method according to claim 1, wherein the coil winding step contacts the n-th layer and winds the n-th layer when the rectangular wire is superimposedly wound from the n-th layer to the (n + 1) -th layer. A method of manufacturing a stator for a wheel-in motor, comprising: moving a winding position while winding the square wire along a guide obliquely crossing a turning direction. 10. The method according to claim 1, wherein the coil forming step presses the divided stator pieces into a predetermined shape while supporting the laminated electromagnetic steel sheets from both sides with support blocks and maintaining the laminated arrangement. A method for manufacturing a wheel-in motor stator. 11. The method according to claim 1, wherein, in the connecting step, after the ends of the coils are crimped in a state of being raised from the coil winding surface, a crimped portion is inserted into an empty space of the wound coil. A method for manufacturing a wheel-in motor stator. 12. The method according to claim 1, wherein the molding step comprises using a mold in which a plurality of separable mold pieces are combined, and removing the stator from the mold after hardening the resin, the bolt is attached to the mold piece. A method of manufacturing a stator of a wheel-in motor, wherein the method is performed by a biasing force of a bolt with respect to the stator when the screw is screwed.