JP2002247813A - Method and device for manufacturing motor, and metal mold and motor for forming integral insulation of stator core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for motor capable of eliminating need for strict control of the laminating thickness of the stator core without using a complicated and expensive metal mold for forming integral insulation of a stator core and capable of preventing generation of wastes such as burrs. SOLUTION: This manufacturing method forms a forming space by inserting the stator core having slots for storing wirings into the metal mold, and forms an insulation layer on the surface of the stator core by injecting resin into the forming space. Resin burring is generated in the slots by setting the dimension of the metal mold so as to be smaller than a core thickness after the closing work of the stator core, and the burring section is bent to be integrated with the insulation layer in the slot.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a motor for integrally insulating a stator core from an insulating resin material, and a mold for integrally insulating a stator core.

[0002]

2. Description of the Related Art A motor core is formed by integrating a hollow disk-shaped core material having a projection on its inner diameter by laminating and pressing, caulking or welding. The hollow disk-shaped core material is formed by punching by press working. The method of insulating a stator core with a thin-film resin is now common as a motor insulation method. In the method of insulating with a thin film of resin, the stator core is set in a resin molding die, the stator core is inserted into the die, and the vicinity of the center of the teeth is supported by a support provided in the die. In this state, injection molding is performed by injecting a resin into a mold, and a resin layer is formed in an area of the surface of the stator core that contacts the winding.
It has been introduced into various motors because it is more reliable than the conventional insulating method using film insertion or ultraviolet curing resin.

An important factor in the integral insulation molding is a deviation in the thickness of the stator core. Since the stator core is formed by stacking and caulking magnetic steel sheets, the thickness of the magnetic steel sheet alone varies due to thickness deviation. Since the stator core is fixed by a mold at the time of molding, burrs may be generated due to the deviation of the accumulated thickness.

[0004] In the integral insulation molding, various measures have been proposed to suppress the occurrence of burrs due to the deviation of the core thickness.
FIG. 30 is a longitudinal cross-sectional view of a main part of a stator core integral molding die in which, for example, a stator core disclosed in JP-A-6-141517 does not generate burrs even if the total thickness varies. . In the figure, 14 is an upper mold, 1
5 is a lower mold. The lower mold 15 includes a core 28 for molding the inner periphery of the stator, and a core insert 27 that is arranged on the outer periphery of the core 28 and forms a molding space in which the stator core 1 is arranged. A sliding mold 23 that forms a molding space below the stator is relatively movably disposed immediately below the stator core 1 of the core insert 27, and the sliding mold 23 slides in accordance with the core thickness. This keeps the core fixed pressure constant and prevents burrs.

[0005]

SUMMARY OF THE INVENTION The above-mentioned Japanese Patent Laid-Open No. 6-141 is disclosed.
No. 517 discloses a stator core integrated molding die that has a complicated die structure and requires complicated pressure control for mold clamping. The mold is slid by applying pressure, which causes a problem of abrasion of the mold. Since the abrasion occurs, periodic maintenance of the mold is required. Also,
Since the mold is complicated, there is a problem that enormous cost and time are required for the maintenance.

In addition, in the integral insulation molding in which the stator core is insulated with a thin film resin, if a complicated and expensive mold for preventing burrs is not used, burrs are generated in the slots due to differences in the thickness of the cores. . This is because a gap is formed in the parting line of the mold in the slot. For this reason, in order to prevent the occurrence of burrs, it is necessary to strictly control the thickness of the sheet.

However, regarding the electromagnetic steel sheet, the difference in the coating also affects the insulation molding. There are several types of coatings on the electromagnetic steel sheet, and even if the thickness of the coating itself is the same, it changes due to the difference in surface roughness, that is, the roughness of the coated surface. By clamping the core, the lamination thickness is different due to the difference in coating after clamping at a constant pressure. The core thickness after clamping also changes depending on other core materials. This is because the force to return to the core appears as a difference in the reaction force of the magnetic steel sheet itself. Therefore, even if the lamination thickness is the same, the core thickness after mold clamping changes due to the difference in coating and magnetic steel material, and burrs are generated. Therefore, it is practically difficult to strictly control the lamination thickness to prevent burrs. Met.

The present invention has been made in order to solve the above-mentioned problems, and strict management of the laminated thickness of the stator core is possible without using a complicated and expensive mold for integrally insulating the stator core. It is an object of the present invention to provide a method and apparatus for manufacturing an electric motor that is unnecessary and does not generate burr waste, and a mold for integrally insulating a stator core.

[0009]

According to a method of manufacturing an electric motor according to the present invention, a molding space is formed by inserting a stator core having a slot for accommodating a winding into a mold, and a resin is injected into the molding space. In a method for manufacturing an electric motor in which an insulating layer is formed on a surface of a stator core, a mold size is set to be smaller than a core thickness of the stator core after clamping, resin burrs are generated in the slots, and the burrs are bent and the slots are bent. Integrated with the insulating layer.

In addition, a burr having a constant width is formed along the inner wall of the slot.

Further, a thin film one surface burr is formed on one surface of the slot.

After the burr is generated in the slot,
The jig in the slot is inserted into the slot, the burr is bent or cut, and then the burr is bent, and the burr is bonded to the insulating layer in the slot by the heat of the jig in the slot.

Further, before the jig in the slot is inserted into the slot, the jig is heated in advance.

After the burr is bent by the jig in the slot, the jig in the slot is heated in that state.

After the burr is generated in the slot,
The jig in the slot is inserted into the slot, the burr is bent or cut, and then the burr is bent, and then the burr is bonded to the insulating layer in the slot by ultrasonic welding.

Further, the process of bonding the burrs is incorporated into the process of the insulation test of the stator.

Also, the position of the burr in the axial direction in the slot is set to a position close to one of the end faces of the stator core, and the burr integrated with the insulating layer in the slot is used as a guide to guide the burr from one core end face side. A winding is inserted.

Further, in a method for manufacturing a motor, a stator core having a slot for accommodating a winding is inserted into a mold to form a molding space, and a resin is injected into the molding space to form an insulating layer on the surface of the stator core. The size of the mold is set smaller than the core thickness of the stator core after clamping, a burr having a constant width is formed along the inner wall of the slot, and the winding is inserted inside the burr.

Further, the winding is fixed by a fixed width burr.

[0020] A mold for integral insulation molding of a stator core according to the present invention is a mold for integral insulation molding of a stator core having an upper mold, a lower mold, and a die in slot. Is set smaller than the core thickness after mold clamping.

The in-slot mold tool has an upper mold tool and a lower tool tool, and the parting surface of the upper tool tool and the lower tool tool has a stepped shape. It is.

The parting surfaces of the upper and lower mold dies have a convex portion on one side and a concave portion on the other side, and the outside of the convex portion communicates with the insulating molding space to form a convex part. The shape part and the concave part are fitted so as to be cut off from the insulating molding space.

Further, the fitting distance of the fitting portion between the convex portion and the concave portion is made larger than the difference between the maximum value and the minimum value of the core thickness after clamping of the stator core.

The in-slot mold tool has an upper mold tool and a lower tool tool, and the parting surfaces of the upper tool tool and the lower tool tool are planar. .

In the electric motor manufacturing apparatus according to the present invention, a molding space is formed by inserting a stator core having a slot for accommodating a winding into a mold, and a resin is injected into the molding space to form an insulating layer on the surface of the stator core. In the electric motor manufacturing apparatus, the mold dimensions are set to be smaller than the core thickness of the stator core after mold clamping, and a mold for integral insulation molding of the stator core that generates resin burrs in the slots, and the burrs are bent. And a jig in the slot to be integrated with the insulating layer in the slot.

Further, the jig in the slot for processing a flash having a constant width formed along the inner wall of the slot has a cylindrical shape.

Further, the tip of the jig in the slot for processing the flash on the entire surface of the thin film formed on one surface of the slot is formed sharp.

The test jig used for the stator insulation test is also used as the jig in the slot.

The electric motor according to the present invention is provided with a burr having a fixed width at at least one axial end in the slot of the stator core.

Further, the winding is inserted from the end on the side with the burr having a certain width.

[0031]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the integral insulation molding of the stator core, insulation burrs are positively generated, and the burrs have a limited width or a mold structure that becomes a thin film one-sided burr, so that the conventional mold configuration remains unchanged. Furthermore, insulation is further ensured by the burr treatment, and the yield in mass production is improved.

FIG. 1 is a perspective view showing a stator core before molding, and FIG. 2 is a perspective view of a tooth portion. Stator core 1
Are stacked by caulking and crimping a plurality of electromagnetic steel sheets. Stator core 1 has teeth 2 and slots 5
There is a space in the slot portion 5 for inserting a winding at the time of winding. The teeth portion 2 plays a role of a magnetic path through which a magnetic field line for rotating the rotor passes.

FIG. 3 is a partial perspective view of a stator core formed with a thin insulating layer, FIG. 4 is an enlarged perspective view of a tooth portion, and FIG. 5 is an enlarged view of FIG. As shown in FIGS. 3 and 4, the stator core 1 is insulated by forming a thin insulating layer at a place where insulation is required. As shown in FIG. 5, a resin layer is uniformly formed in the slot where the winding contacts except for the inner peripheral surface of the tooth tip of the teeth portion 2 and on both end surfaces of the core through which the winding passes.

FIG. 6 is a sectional view of a stator on which windings are applied.
FIG. 7 is a perspective view of a stator on which windings are applied. As shown in FIG. 6, the winding part 6 is completely insulated from the stator core 1 by the thin insulating layer formed on the stator core 1. Further, as shown in FIG. 7, at this time, the winding portion 6 is configured to protrude up and down from both end surfaces of the core, and the portion protruding up and down is referred to as a coil end 25. The coil end 25 is an assembly of windings. However, when molding is performed thereafter, the windings may be unwound by the resin pressure of the mold, and may come into contact with the stator core 1. By performing the integral insulation molding, most of the stator core 1 is insulated, so that even if the windings are disturbed, there is little possibility that insulation failure occurs.

Next, the configuration of a mold in integral insulation molding will be described. FIG. 8 is a schematic view of a mold in integral insulation molding. As shown in the figure, the mold includes an upper mold 14 and a lower mold 15.
And an in-slot die recorder 16. The figure shows a state where the stator core 1 is inserted into the lower mold 15 and the upper mold 14 is closed. At the time of insulating molding, resin is injected from the gate 13 to form an insulating portion 3 on a predetermined surface of the stator core 1.

Next, the flow from the integral insulation molding to the winding will be described. FIG. 9 is a flowchart showing the flow from the integral insulation molding to the winding. First, the stator core 1 is inserted into the lower mold 15 (step S1). At this time, the lower mold 15
And the stator core 1 are heated to the same temperature. Next, the upper mold 14 is lowered to close the mold, and the stator core 1 is compressed (step S2). Thereafter, the resin is injected from the gate 13 by an injection molding machine and molded (step S3).
After the injection, the mold is opened, the runner of the gate 13 is removed (Step S4), and the molded stator core 1 is separated from the mold with an ejector pin and taken out (Step S4).
5).

With the stator core 1 formed as an integral insulator removed from the mold, a burr processing jig is inserted into the slot to process the burr (step S6). The stator core 1 after the burr treatment is put into a winding machine to perform winding (step S7). The windings are mounted and the electric terminals are attached to complete the stator (step S8). Although the details of the burr treatment will be described later, by heating the burr treatment jig inserted into the slot, the resin becomes soft and the burr treatment can be easily performed.

In the winding step, there is a method in which a large number of windings are wound in an arc shape and inserted by a winding jig. in this case,
Since the coil is inserted into the slot, it is necessary to have a structure in which the winding is easily inserted in the slot. Therefore, the insulating film is designed to be as thin as possible.

Here, a description will be given of the state at the time of integral insulation molding in the case where the stack thickness of the stator core 1 is smaller than the design value and in the case where it is thicker. When the core thickness is excessively thinner than the design value, the core pressing on the inner and outer circumferences shown in FIG. 8 is not effective. As a result, a gap is generated in a portion where the resin is filled, and burrs are generated on the inner and outer circumferences of the stator core. The burrs flow into the side surface of the stator core 1 to form a uniform resin surface on the side surface of the core, and the resin film cannot be separated. And processing becomes difficult.

When the core thickness is larger than the design value, burrs are generated at the mating portion of the in-slot die 16 inserted into the slot. Injection molding is possible even if the core thickness of the in-slot die 16 is greater than the core thickness, which is the design value of the die. This is because the core has a spring-like shape in which the entire core is compressed by the pressure of the mold. Further, even if the upper mold 14 and the lower mold 15 are not completely closed, the resin inflow path is maintained, so that injection is possible. However, at this time, a gap is generated between the upper mold insert in the slot and the lower mold insert in the slot inserted into the slot,
The gap is filled with resin to form burrs. In the present invention, burrs are easily performed by a method described later.

The compression ratio by mold clamping differs depending on the type of the magnetic steel sheet. For example, 96.8% for MSB-3, NC-F
In M, it is 97.4%. The design dimensions of the mold are derived from the compressibility of the material. FIG. 10 is a conceptual diagram showing the mold thickness, the burr generation range, and the burr generation tolerance from the core thickness. Since the compression ratio by mold clamping is determined by the material of the core, the range of burrs can be assumed from the product of the difference between the maximum width and the minimum width of the stator core by the core and the compression ratio. In addition, the dimensions of the mold can be set based on the compression ratio × the minimum core thickness of the stator core. In this way, a design corresponding to the core material and the core coating is possible.

Here, the mold of the present invention will be described.
With reference to FIGS. 11 to 17, description will be made on insulation molding when a step is provided in a mold. FIG. 11 shows an insulation molding state at an appropriate core thickness when a step is set in the mold. In this case, no burr occurs in the slot.

FIG. 12 shows an insulation molding state when the core thickness is increased when a step is set in the mold. In this case, a burr 9 having a constant width is generated on the mold parting surface 8 in the slot. .

FIG. 13 shows the stator insulation and the upper and lower molds in the slot after the mold is closed and resin is injected when the core thickness is increased when the mold has a step in the cross section taken along the line BB in FIG. This shows the state of the mold. Steps are set in the upper die stamp 10 in the slot and the lower die stamp 11 in the slot,
The convex and concave fitting portions generate burrs of a fixed width by blocking from the molding space. FIG. 13 omits the peripheral mold.

The state of the mold in the slot at this time is shown in FIG.
FIGS. 14 and 15 are enlarged views of part A of FIG. Figure 1
Reference numeral 4 denotes a case where the core thickness is the minimum, the mold in the slot is completely fitted, and the mold parting surface 8 is in close contact, so that no resin flows from the insulating portion 3. Reference numeral 21 denotes an upper mold wrench 10 in the slot and a lower mold wrench 11 in the slot.
The fitting distance 22 is a mold fitting portion.

Next, when the core thickness is larger than the minimum, FIG.
As shown in FIG. 5, the mold fitting portion 22 is tightly fitted, but since the core thickness is larger than that in FIG. 14, the upper mold dies 10 in the slot move upward and the resin flows into the slot. A burr 9 having a constant width is formed. The upper mold dies 10 in the slot slide upward. Originally, since the upper mold is fixed by sliding the upper mold, the resin does not flow into the space gap 12 from the mold fitting portion 22, and a fixed width burr 9 is generated in a portion outside the space gap 12. . Note that the fitting distance 21 is a margin for the change in the core thickness (see FIG. 10).

The burr is positively generated for the increase in the core thickness. After the molding, as shown in FIG. 16, the upper mold dies 10 in the slots are lifted, and then the insulated stator core is ejected (FIG. 17). At this time, the state of the fixed-width burr 9 does not change, and becomes a burr having a fixed width toward the center in the slot, so that the burr can be easily processed.

The case where no step is set in the mold is as follows. FIG. 18 shows the case where the core thickness is the minimum. Similar to FIG. 11, the mold inside the slot is completely fitted, the parting surface 8 in the slot is in close contact, and no burr is generated. Next, when the core thickness is larger than usual, burrs 7 are generated on the entire surface of the thin film as shown in FIG. The upper mold die recorder 10 in the slot moves upward by the thickness of the core and the resin flows into the slot, thereby forming the thin film one-sided burr 7.

Next, a method of the flash processing will be described. In the case of a fixed-width burr 9, as shown in FIG. 20, a cylindrical in-slot jig 19 is inserted into the slot toward the fixed-width burr 9. In order to bend and stretch the fixed-width burr 9 in the slot to make it tight, the jig 19 in the slot is raised to a temperature at which the resin becomes soft and then inserted into the slot (FIGS. 21 and 22).

Alternatively, the jig 1 in the slot in the state of FIG.
9 may be heated to bring the burr into close contact. This is possible because the resin used as the insulating material is a thermoplastic resin.

Further, bonding by ultrasonic welding after bending by the jig 19 in the slot is also possible.

A burr 9 having a constant width is formed by the burr treatment as described above.
The bent portion becomes a double insulating layer, and the insulating property can be further improved.

In the case of the thin film burr 7 as shown in FIG. 23, the jig 19 in the slot is inserted into the slot with respect to the thin film burr 7 in the slot. At this time, the jig 19 in the slot has a sharp tip so that the thin film can be easily cut. Next, as shown in FIG. 24, the thin film one-sided burr 7 is cut, and by inserting the jig 19 in the slot as it is, the burr 7 can be laid down and extended. Further, FIG.
In the state shown in (1), the jig 19 in the slot is raised to a temperature at which the resin becomes soft, and the thin film one-sided burr 7 is adhered.

Alternatively, the jig 19 in the slot may be raised to a temperature at which the resin becomes soft, and then inserted into the slot.

After bending by the jig 19 in the slot, bonding by ultrasonic welding is also possible.

The portion where the thin film burr 7 is bent by the burr treatment as described above becomes a double insulating layer and becomes stronger. The area of the double insulating layer is larger than that of the fixed-width burr 9, and the insulation can be further strengthened.

Further, it is not necessary to newly provide a burr treatment step by incorporating the burr treatment into, for example, a withstand voltage test step in an insulation inspection of the stator.

The in-slot mold parting surface 8 is determined for winding. The position of the fixed width burr 9 from the vicinity of the core end face can be changed by changing the in-slot die 16. For example, as shown in FIGS. 26 to 28, the position of the fixed-width burr 9 is set closer to the core end face portion. Then, the winding is inserted from the end on the side where the burr has a certain width. At this time, the fixed-width burr 9 which is tilted when the winding bundle is inserted by the winding machine plays a role of a guide for the winding jig 24, and has an effect of suppressing the fluttering of the winding when the winding is inserted.
Since the winding jig 24 is smaller than the diameter of the winding bundle, there is an insulating guide, so that the positional accuracy at the time of winding is improved, the defect rate is reduced, and the reliability is improved. In addition, the insulation strength is improved by a certain amount of burr.

When the winding coating is strong,
The insulation layer may be shaved by the winding and the core may be exposed and the winding may be short-circuited, but the insulation effect can be maintained by using double insulation for the portion having a large friction against it. In addition, the location can increase the insulation distance.

When the winding is inserted, a double portion of insulation (a portion with a fixed width burr) serves as a guide, and the insulation at the insertion opening of the winding is double and is strong against insertion friction. For this reason, insulation failure does not occur even if the windings are repeatedly inserted during recycling. Therefore, after the motor is disassembled, the stator core insulation can be repeatedly reused and recycled, and a highly reliable electric motor can be obtained.

FIGS. 26 to 28 illustrate the case of the fixed width burr 9, but the same can be said of the case of the thin film one-sided burr 7.

If the number of windings is small depending on the model, it is not necessary to process the fixed-width burr 9. The windings are bundled by the fixed-width burrs 9, and the windings are located at the center in the slot, which is an ideal arrangement. In addition, since the winding is fixed, the winding does not flutter during molding, which is effective for improving the quality.

As shown in FIGS. 26 to 28, the insertion direction of the winding and the processing direction of the burr generated on the parting surface 8 of the mold in the slot are set to be the same. As a result, as shown in FIG. 29, the core end face from which the lead wire connected to the terminal 26 comes out and the core end face near the burr become the same.

[0064]

According to the method of manufacturing an electric motor according to the present invention, the size of the mold is set to be smaller than the core thickness of the stator core after the mold is clamped, resin burrs are generated in the slots, and the burrs are bent so that the burrs are bent. Integrated with the insulating layer of
Strict control of the core thickness is not required, and no burrs are removed, so no waste is generated and it is environmentally friendly. In addition, even if the magnetic steel sheet changes in core thickness or the coating of the magnetic steel sheet is different, it can be used without distinction.

Further, since a burr having a constant width is formed along the inner wall of the slot, burr processing can be easily performed, insulation is ensured by the burr processing, and the yield in mass production is improved.

Further, since a thin film burr is formed on one side of the slot, insulation is further ensured by burr processing, and the yield in mass production is improved.

After generating burrs in the slots,
Insert the jig in the slot into the slot, bend or cut the burr, then bend the burr, and bond the burr to the insulating layer in the slot by the heat of the jig in the slot. Does not occur, and the insulation is reinforced.

Further, since the jig in the slot is heated before being inserted into the slot, the jig can be easily bonded to the insulating layer in the slot while bending the burr.

After the burr is bent by the jig in the slot, the jig in the slot is heated in that state, so that it can be easily bonded to the insulating layer in the slot.

Since the burr is bonded to the insulating layer in the slot by ultrasonic welding after the burr is bent, the burr can be bonded to the insulating layer in the slot more reliably.

Also, since the process of bonding burrs is incorporated into the process of the insulation test of the stator, it is not necessary to newly provide a burring process.

Further, the axial position of the burr in the slot is set to a position close to one of the end faces of the stator core, and the burr is integrated with the insulating layer in the slot. Since the winding is inserted from the core end face side, it is possible to suppress fluttering of the winding when the winding is inserted. In addition, since there is a burr having a constant width, the insulation is doubled, and insulation failure can be reduced.

Further, since the size of the mold is set smaller than the core thickness of the stator core after clamping, a burr having a constant width is formed along the inner wall of the slot, and the winding is inserted inside the burr.
Burr processing becomes unnecessary.

Further, since the windings are fixed by the fixed width burrs, the windings are united, and the windings are ideally arranged near the center in the slot.

In the mold for integral insulation molding of the stator core according to the present invention, since the dimensions of the mold are set smaller than the core thickness of the stator core after clamping, a predetermined burr can always be generated in the slot.

Further, since the parting surfaces of the upper and lower mold dies in the slot mold dies are stepped, a burr having a constant width can be formed.

The parting surfaces of the upper and lower mold dies have a convex portion on one side and a concave portion on the other side, and the outside of the convex portion communicates with the insulating molding space to form a convex part. Since the shape portion and the concave shape portion are fitted so as to be cut off from the insulating molding space, it is possible to reliably form a fixed-width burr.

Further, since the fitting distance of the fitting portion between the convex portion and the concave portion is made larger than the difference between the maximum value and the minimum value of the core thickness after mold clamping of the stator core, the core thickness varies. However, a fixed-width burr can be surely formed.

The in-slot mold tool has an upper tool tool and a lower tool tool, and the parting surfaces of the upper tool tool and the lower tool tool are planar.
Burr can be formed on one surface of the thin film.

The apparatus for manufacturing a motor according to the present invention is characterized in that the mold dimensions are set to be smaller than the core thickness of the stator core after the mold is clamped, and a mold for integral insulation molding of the stator core that generates resin burrs in the slots; With a jig in the slot that bends the burr and integrates it with the insulating layer in the slot, strict management of the core thickness is not required, and no waste is generated because the burr is not scraped off, and the environment is not affected. friendly. In addition, even if the magnetic steel sheet changes in core thickness or the coating of the magnetic steel sheet is different, it can be used without distinction.

Further, since the jig in the slot for processing the fixed-width burrs formed along the inner wall of the slot has a cylindrical shape, the fixed-width burrs can be easily processed with a simple apparatus configuration.

Further, by forming the tip of the jig in the slot for processing the flash on the entire surface of the thin film formed on one surface of the slot to be sharp, the flash on the entire surface of the thin film can be easily cut.

Further, since the test jig used for the insulation test of the stator is also used as the jig in the slot, it is not necessary to manufacture a new jig in the slot.

Since the electric motor according to the present invention is provided with a burr having a fixed width at least in one axial end portion in the slot of the stator core, even if the winding is repeatedly inserted at the time of recycling, the insulation does not decrease.

Further, by inserting the winding from the end on the side where the burr of a certain width is present, the insulation strength is improved by the amount of the burr of a certain width.

[Brief description of the drawings]

FIG. 1 shows the first embodiment and is a perspective view showing a stator core before molding.

FIG. 2 shows the first embodiment, and is a perspective view of a teeth portion.

FIG. 3 shows the first embodiment and is a partial perspective view of a stator core on which a thin insulating layer is formed.

FIG. 4 is a diagram showing the first embodiment, and is a perspective view in which a tooth portion is enlarged.

FIG. 5 is an enlarged view of FIG.

FIG. 6 shows the first embodiment, and is a cross-sectional view of a stator on which windings are applied.

FIG. 7 is a view showing the first embodiment, and is a perspective view of a stator on which windings are applied;

FIG. 8 shows the first embodiment, and is a schematic view of a mold in integral insulation molding.

FIG. 9 shows the first embodiment, and is a flowchart showing a flow from integral insulation molding to winding.

FIG. 10 is a diagram showing the first embodiment, and is a conceptual diagram of a mold thickness, a burr generation range, and a burr generation tolerance from a core thickness.

FIG. 11 is a view showing the first embodiment, and is a perspective view showing an insulating state at a proper core thickness when a step is set in a mold.

FIG. 12 is a view showing the first embodiment, and is a perspective view showing an insulation molding state when a core thickness is increased when a step is set in a mold.

13 is a diagram showing Embodiment Mode 1, and is a cross-sectional view taken along line BB of FIG. 12;
FIG. 9 is a cross-sectional view showing an insulating molding state after the mold is closed and resin is injected and a state of the upper and lower molds in the slot when the core thickness is increased when a step is set in the mold in the line cross section.

FIG. 14 is an enlarged view of a portion A in FIG. 13 and is an enlarged view of an insulation molding state and a state of a mold in a slot when a core thickness is appropriate when a step is set in the mold.

FIG. 15 is an enlarged view of a portion A in FIG. 13, and is an enlarged view of an insulating molding state and a state of a mold in a slot when a core thickness is increased when a step is set in the mold.

FIG. 16 is a view showing the first embodiment, and is a cross-sectional view showing a state in which the upper die in the slot is removed after insulation molding when a step is set in the die.

FIG. 17 is a view showing the first embodiment, and is a cross-sectional view showing a state where the stator insulation is ejected after insulation molding when a step is set in the mold.

FIG. 18 is a view showing the first embodiment, and is a perspective view showing an insulating state when the core has an appropriate thickness when no step is set in the mold.

FIG. 19 is a view showing the first embodiment, and is a perspective view showing an insulation molding state when the core thickness is increased when no step is set in the mold.

FIG. 20 is a view showing the first embodiment, and is a cross-sectional view showing a state in which insertion of a burr processing jig into a stator after insulation molding has started when a step is set in a mold.

FIG. 21 is a view showing the first embodiment, showing a state in which a fixed-width burr is deformed by a burr-processing jig and started to fall down on a stator after insulation molding when a step is set in a mold. It is sectional drawing.

FIG. 22 is a view showing the first embodiment, in which a fixed width burr is deformed by a burr processing jig on a stator after insulation molding in a case where a step is set in a mold, and the stator is brought into close contact with an insulating portion. FIG.

FIG. 23 shows the first embodiment, and is a cross-sectional view showing a state where insertion of a burr processing jig into a stator after insulation molding is started when no step is set in a mold.

FIG. 24 shows the first embodiment, and inserts a burr processing jig into a stator after insulation molding when no step is set in a mold, cuts a thin film burr, and attaches the thin film burr to an insulating portion. FIG. 6 is a cross-sectional view showing a state in which

FIG. 25 is a view showing the first embodiment, in which a burr processing jig is inserted into a stator after insulation molding when a step is not set in a mold, and a thin film burr is brought into close contact with an insulating portion. FIG.

FIG. 26 is a diagram showing the first embodiment, and is an enlarged view of a state in which insertion of a burr processing jig into a stator after insulation molding is started when a step is set in a mold. .

FIG. 27 is a diagram showing the first embodiment, in which a burr processing jig is inserted into a stator after insulation molding when a step is set in a mold, and a fixed-width burr is brought into close contact with the insulating portion. It is an enlarged view showing a state.

FIG. 28 is a view showing the first embodiment, in which a burr processing jig is inserted into a stator after insulation molding when a step is set in a mold, and a fixed-width burr is brought into close contact with the insulating portion. It is an enlarged view which shows the state which inserts a winding later.

FIG. 29 is a diagram showing the first embodiment, and is an enlarged view showing a state where insertion of a winding into the stator after insulation molding is completed.

FIG. 30 is a longitudinal sectional view of a main part of a conventional stator core integral molding die.

[Explanation of symbols]

1 stator core, 2 teeth part, 3 insulation parts, 5
Slot part, 6 Winding part, 7 Thin film one-sided burr, 8 Slot parting surface in slot, 9 Constant width burr, 10 Upper slotting tool in slot, 11 Lower slotting tool in slot, 12 Spacing, 13 Resin gate , 14 Upper die, 15 Lower die, 16 Slot die die, 19
Jig in slot, 21 fitting distance, 22 mold fitting part, 24 winding jig, 25 coil end, 26 terminals.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Mineo Yamamoto, 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsui Electric Co., Ltd. (72) Hiroyuki Ishii 2-3-2, Marunouchi, Chiyoda-ku, Tokyo Inside Rishi Electric Co., Ltd. (72) Inventor Shuichi Iwata 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric Corporation F-term (reference) 5H002 AA08 AB01 AB04 AC07 5H604 AA05 AA08 BB01 BB08 BB14 CC01 CC05 CC13 DB03 PB03 PE06 QA03 5H615 AA01 BB01 BB05 BB14 PP06 PP13 RR07 SS03 SS05 SS13 SS18 SS44 TT32

Claims (22)

[Claims] 1. A method for manufacturing a motor in which a stator core having a slot for accommodating a winding is inserted into a mold to form a molding space, and a resin is injected into the molding space to form an insulating layer on the surface of the stator core. In the above, the mold dimensions are set smaller than the core thickness of the stator core after clamping, so that burrs of the resin are generated in the slots, and the burrs are bent and integrated with the insulating layer in the slots. A method for manufacturing a motor, comprising: 2. The method according to claim 1, wherein a burr having a constant width is formed along the inner wall of the slot. 3. The method according to claim 1, wherein a thin film burr is formed on one surface of the slot. 4. After the burr is generated in the slot, a jig in the slot is inserted into the slot, and the burr is bent or cut, and then the burr is bent. 2. The method according to claim 1, wherein the burr is adhered to the insulating layer in the slot. 5. The apparatus according to claim 4, wherein the jig in the slot is heated before being inserted into the slot.
The manufacturing method of the electric motor according to the above. 6. The method for manufacturing an electric motor according to claim 4, wherein after the burr is bent by the jig in the slot, the jig in the slot is heated in that state. 7. After the burr is generated in the slot, a jig in the slot is inserted into the slot, and the burr is bent or cut and then the burr is bent. 2. The method according to claim 1, wherein burrs are bonded to the insulating layer in the slots. 8. The method for manufacturing an electric motor according to claim 6, wherein the process of bonding the burrs is incorporated into a stator insulation test process. 9. An axial position of the burr in the slot is set to a position near one end face of the stator core, and the burr integrated with an insulating layer in the slot serves as a guide. 2. The method for manufacturing an electric motor according to claim 1, wherein a winding is inserted from the end face of the core. 10. A method for manufacturing an electric motor, wherein a stator core having a slot for accommodating a winding is inserted into a mold to form a molding space, and a resin is injected into the molding space to form an insulating layer on the surface of the stator core. In the electric motor, the mold dimensions are set smaller than the core thickness of the stator core after clamping, a fixed-width burr is formed along the inner wall of the slot, and a winding is inserted inside the burr. Production method. 11. The method of manufacturing an electric motor according to claim 10, wherein said winding is fixed by said fixed width burr. 12. A mold for integral insulation molding of a stator core having an upper mold, a lower mold, and an in-slot mold wrench, wherein the mold dimension is set to be smaller than the core thickness of the stator core after mold clamping. A mold for integral insulation molding of a stator core, characterized in that: 13. The in-slot mold insert has an upper mold insert and a lower mold insert, and a parting surface of the upper mold insert and the lower mold insert has a stepped shape. 13. The mold for integral insulation molding of a stator core according to claim 12, wherein: 14. A parting surface of the upper mold tool and the lower mold tool has one convex part and the other part has a concave part, and the outside of the convex part communicates with an insulating molding space. 14. The mold for integral insulation molding of a stator core according to claim 13, wherein the convex and concave portions are fitted so as to be shut off from the insulation molding space. 15. A fitting distance of a fitting portion between the convex portion and the concave portion is larger than a difference between a maximum value and a minimum value of a core thickness of the stator core after mold clamping. A mold for integral insulation molding of the stator core according to claim 14. 16. The in-slot mold insert has an upper mold insert and a lower mold insert, and a parting surface of the upper mold insert and the lower mold insert has a planar shape. 13. The mold for integral insulation molding of a stator core according to claim 12, wherein: 17. An electric motor manufacturing apparatus in which a stator core having a slot for accommodating a winding is inserted into a mold to form a molding space, and a resin is injected into the molding space to form an insulating layer on the surface of the stator core. In the above, the dimensions of the mold are set smaller than the core thickness of the stator core after clamping, and a mold for integral insulation molding of the stator core for generating burrs of the resin in the slot; A jig in a slot integrated with an insulating layer in the motor. 18. The electric motor manufacturing apparatus according to claim 17, wherein the jig in the slot for processing a fixed-width burr formed along the inner wall of the slot has a cylindrical shape. 19. The apparatus for manufacturing an electric motor according to claim 17, wherein a tip of said jig in the slot for processing a thin film one-sided burr formed on one side of the slot is formed sharp. 20. The electric motor manufacturing apparatus according to claim 17, wherein a test jig used for an insulation test of the stator is also used as the jig in the slot. 21. An electric motor characterized in that at least one axial end of a slot in a stator core is provided with a burr having a constant width. 22. The electric motor according to claim 21, wherein a winding is inserted from an end on a side having a burr of a fixed width.