JP2009232522A - Method for manufacturing split stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a split stator for surely keeping a space of, for example, 0.2 mm or more, between molded coils. <P>SOLUTION: In the method for manufacturing the split stator for molding a resin mold around the periphery of an edgewise coil 13 mounted on a divided core 10 via an insulator 12, the divided core being inserted into a fixed die 21 and a movable die 22, the resin mold is molded under the condition that the outer peripheral surface of the edgewise coil 13A and a part of the surface adjacent to the other edgewise coil 13B in a product state is brought into direct contact with the upper part of the projected part 22b formed on the projected part 22a of the movable die 22. In the method, pressing force is applied to respective windings 13c, 13d, 13e, 13f, etc., of the edgewise coil 13, while respective windings 13c, 13d, 13e, 13f, etc., of the edgewise coil 13 are positioned by the projected part 22b, preventing the respective windings from moving outside further than the upper part of the projected part 22b. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a motor split stator manufacturing method capable of accurately and reliably ensuring an insulation distance between coils.

A method is known in which a stator core is formed by laminating steel plates punched by press working, and a stator is manufactured by injection molding a resin in a winding portion or the like in a state where the winding is assembled.
On the other hand, a method of using a divided stator in which a stator core is divided into a plurality of parts and windings are assembled is also known as a method for manufacturing a stator. In the case of a split stator, a plurality of split stators are integrally assembled by baking baffling.
Patent Document 1 describes that a molded coil is attached to a split core. In the illustrated drawings, adjacent formed coils are in contact with each other, but there is a problem in terms of ensuring insulation between the coils.
In order to solve this problem, interphase insulating paper is mounted between the formed coils.

JP 2006-166610 A

However, the method of attaching interphase insulating paper between the formed coils includes positioning problems when setting interphase insulating paper, cost increases due to the installation of interphase insulating paper, and interphase in the resin molding process, which is a subsequent process. There was a problem of defects due to insulation paper defects.
On the other hand, if the gap between the coils can be reliably secured, for example, 0.2 mm or more without using interphase insulating paper, insulation can be ensured by the space, but the outer peripheral dimensions of the insulator attached to the split stator core Since there is a tolerance between the inner diameter of the molded coil and the inner circumference of the molded coil, when resin molding is performed, resin is injected at a high pressure, and the resin pressing force is directly applied to the molded coil. The position of the coil deviates from the stator core in the circumferential direction (the direction of the adjacent coil) with a width of +0.3 mm to −0.3 mm. As a result, it has been practically difficult to ensure a clearance of 0.2 mm or more between adjacent coils.

  The present invention is for solving the above-described problems, and a method for manufacturing a split stator that can reliably secure a gap between the formed coils by, for example, 0.2 mm or more by accurately positioning the formed coils. The purpose is to provide.

In order to achieve the above object, the split stator manufacturing method of the present invention has the following configuration. (1) A split stator manufacturing method in which a resin is molded around a molded coil inserted into a split mold and attached to a split core via an insulator. Then, resin molding is performed in a state where a part of a surface adjacent to another molded coil in a product state is in direct contact with a molding die.
(2) In the split stator manufacturing method described in (1), a portion where the molded coil is in contact with the molding die is a ridge at a central position of the side surface of the slot.

Next, the operation and effect of the method for manufacturing the split stator of the present invention having the above-described configuration will be described.
In the first step of the split stator manufacturing method of the present invention, a split core is set in a first molding die (for example, a fixed die), an insulator is set in a tooth portion of the split core, and a molded coil ( For example, a molded edgewise coil) is set on an insulator.
Next, a second molding die (for example, a movable die) is brought into contact with the first molding die to form a cavity.

At this time, when the ridge is formed at a position corresponding to the outer peripheral surface of the molded coil of the second molding die, and the second molding die and the first molding die come into contact with each other, Resin mold because the tip of the ridge is positioned by abutting the outer periphery of the pre-formed coil against each of the windings wound several times toward the teeth of the split core from both sides When resin is injected into the cavity and high-pressure resin flows in and presses the molded coil, all the windings of the molded coil do not move due to the pressure of the resin, and the molded core has been molded. The coil is accurately positioned. Thereby, the clearance gap between the outer periphery of the adjacent shaping | molding coil can be ensured reliably 0.2 mm or more.
In addition, since the portion in contact with the molded coil is a ridge at the central position of the side surface of the slot, normally, when the resin injection port is provided at both ends of the molded coil, the resin inflow path has the same condition. Therefore, the resin mold resin can be uniformly introduced into the cavity. Moreover, since it is a convex line, since the part in which the resin mold is not formed on the outer periphery of the molded coil is only a predetermined width, it hardly affects the heat radiation from the molded coil.

DESCRIPTION OF EMBODIMENTS Hereinafter, an embodiment embodying a split stator and a split stator manufacturing method according to the present invention will be described in detail with reference to the drawings.
FIG. 1 shows a manufacturing procedure of the split stator. The split stator core 10 includes a tooth portion 11 to which a molded coil is attached. The split stator core 10 is formed by laminating steel plates manufactured by press punching. Here, 18 divided stator cores 10 are combined to form a ring-shaped completed stator core. The split stator core 10 is shown in (a). Next, a state where the insulator 12 is attached to the teeth portion 11 of the split stator core 10 is shown in FIG. The insulator 12 covers the cylindrical portion 12b that covers the tooth portion 11 and the inner surface portion other than the teeth portion 11 of the split stator core 10 that protrudes, and protrudes up and down the cover portion 12a and the cylindrical portion 12b that extend in the vertical direction. Two projections 12c are provided. Here, the thickness of the side surface of the insulator 12b is 0.2 to 0.3 mm. In this embodiment, the insulator is made of PPS resin, which is a thermoplastic resin containing about 50% glass fiber filler.

FIG. 1C shows a view in which the formed edgewise coil 13 is attached to the tooth portion 11 via the cylindrical portion 12b of the insulator 12. FIG. The edgewise coil 13 is formed by forming a coil wire having a flat cross section (rectangular shape) by matching the inner diameter with the shape of the tooth portion 11.
The edgewise coil 13 is in close contact with the split stator core 10 via the cover portion 12a. Further, the edgewise coil 13 is positioned by the teeth portion 11 in the left-right direction via the cylindrical portion 12b. Further, the vertical direction is positioned by the protrusion 12 c of the insulator 12. Thereby, the edgewise coil 13 is positioned at a fixed position with respect to the split stator core 10. The edgewise coil 13 includes a long terminal 13a protruding upward near the cover portion 12a and a long terminal 13b protruding upward near the tip of the tooth portion 11.
In the present embodiment, the edgewise coil 13 will be described as a molded coil. However, any other types of coils may be used as long as the cross section is round, square, or molded and the shape is fixed. is there.

FIG. 1D shows a resin-molded split stator 18. The edgewise coil 13 portion of (c) is resin molded 14. The molding method of the resin mold will be described later in detail. A pair of long terminals 13 a and 13 b protrudes from the resin mold 14 of the split stator 18 to the outside. A concave groove 14a having a predetermined width is formed on each surface of the resin mold 14 in the circumferential direction (both surfaces adjacent to other coils). The concave groove 14a will be described in detail later.
A cross-sectional view of the resin-molded split stator 18 is shown in FIG. This sectional view shows the positional relationship between the edgewise coil 13 and the resin mold 14.
An edgewise coil 13 is attached to the split stator core 10 via an insulator 12, and a resin mold 14 is formed only in a portion surrounding the coil portion of the edgewise coil 13. FIG. 3 shows a state in which a resin-made bus bar holder 16 that holds the bus bar 17 is mounted on the split stator core 10. The long terminals 13a and 13b are bent and connected to the bus bar 17.

FIG. 2 shows a stator 19 in which 18 divided stators 18 are combined. Eighteen split stators 18 are combined in an annular shape, and the outer cylinder 15 that is heated to the outside and expands to increase its inner diameter is fitted. Thereafter, by cooling to room temperature, the inner diameter of the outer cylinder 15 is reduced, and the 18 split stators 18 are tightened and integrated into a stator 19. This is a so-called outer cylinder shrinkage.
In the next step, although not shown, the long terminal 13 a of the split stator 18 is connected to the long terminal 13 b of the third split stator 18 beyond the two split stators on the left side and the bus bar holder 16. Connected by bus bar 17. In this way, the 18 long terminals are sequentially connected by the bus bar 17 in the bus bar holder 16 to constitute three motor coils of U, V, and W phases.

Next, the split stator manufacturing method of the present invention for manufacturing the split stator 18 will be described. 4 to 7 show the steps of the split stator manufacturing method of the present invention. FIG. 8 shows the positional relationship among the teeth portion 11 of the split stator core 10, the insulator 12, and the edgewise coil 13 that are mounted on the fixed die 21.
A molding die structure for molding a resin mold will be described. As shown in FIGS. 4 and 8, the fixed mold 21 as the first mold includes a fixed mold body 21d, a pair of slide molds 21a sandwiching the split stator core 10 from the left and right, and a pair protruding from the fixed mold body 21d. The guide part 21c and the slide mold 21b that is guided and slid by the pair of guide parts 21c are provided.
The split stator core 10 is sandwiched by a pair of slide molds 21a from both sides, and is fixed by a slide mold 21b in a direction orthogonal to the direction in which the slide mold 21a is sandwiched. An insulator 12 is attached to the teeth portion 11 of the split stator core 10. The insulator has a thickness of 0.3 mm in the present embodiment, but is shown thick in order to make it easier to see in the figure.

On the other hand, the shape of the formed edgewise coil 13 is shown in FIG. FIG. 8 is a perspective view showing a structure for holding the edgewise coil 13 by the coil gripping block 20.
As shown in FIG. 8, the edgewise coil 13 includes two long terminals 13a and 13b. The generally cubic coil holding block 20 is formed with holding holes 20a and 20b into which the ends of the long terminals 13a and 13b of the edgewise coil 13 are inserted and fitted. In addition, the coil holding block 20 has an inclined portion on one side.
FIG. 8 shows a state in which the end portions of the long terminals 13 a and 13 b of the edgewise coil 13 are inserted and fitted into the holding holes 20 a and 20 b of the coil holding block 20. In the manufacturing process, a large number of coil gripping blocks 20 are prepared, and the edgewise coil 13 is prepared in advance as shown in FIG. When the molding mold is finished, the coil gripping block 20 is recovered and used as a jig any number of times.

The fixed mold 21 and the movable mold 22 of the present embodiment are lateral fastening molds in which the movable mold moves in the horizontal direction.
As shown in FIG. 4, the coil holding block 20 is mounted on the fixed mold 21 in a state where the split stator core 10 is fixed to the fixed mold 21 and the movable mold 22 as the upper mold is fully opened. As a result, the coil holding block 20 constitutes a part of the fixed mold 21. This state is shown in a perspective view in FIG.
On the other hand, the movable type includes a guide type 26 and a slide type 22. A projecting portion 22 a is formed on the slide mold 22 corresponding to the inner peripheral surface of the slide mold 21 a of the fixed mold 21.

As shown in FIGS. 6 and 7, trapezoidal ridges 22b having a predetermined width are formed in a straight line at the center position of the surface corresponding to the edgewise coil 13 of the protrusion 22a. The surface corresponding to the edgewise coil 13 of the projecting portion 22a is positioned so that the edgewise coil 13 spreads outward as it goes toward the root of the tooth portion 11, and as it goes toward the root of the tooth portion 11. ing. The ridge 22b is formed in parallel to the surface of the protrusion 22a.
The reason why the protrusions 22b are trapezoidal and have a predetermined width on the upper side is to ensure that the windings of the edgewise coils 13 that abut each other are parallel to the movable type.
FIG. 5 shows a closed state in which the guide mold 26 is in contact with the upper surface of the tooth portion 11 and the slide mold 22 is in contact with the slide mold 21a. A cavity space is formed by the outer peripheral surface of the insulator 12 mounted on the outer periphery of the tooth portion 11, the fixed die main body 21 d, the inner peripheral surface of the protruding portion 22 a, and the slide die 22. In this state, the injection of the resin mold resin has not yet started.

At this time, as shown in FIG. 7, with respect to the first winding 13c, the second winding 13d, the third winding 13e, and the fourth winding 13f (not shown) from above the edgewise coil 13, When the upper side of the trapezoidal shape of the ridge 22b comes into contact, all the windings 13c, 13d, 13e, 13f,... Of the edgewise coil 13 are located at the center position of the surface adjacent to the other edgewise coils. It is pressed and positioned in a direction approaching the teeth portion 11 by the upper side portion of the ridge 22b.
Next, as shown in FIG. 10, high-pressure resin of 50 kPa is injected from the two resin mold injection ports 21e. FIG. 10 is a partial cross-sectional view showing a state when the fixed mold 21 and the movable mold 22 are clamped. Since the mold of the present embodiment is a lateral fastening type, the resin mold material 25 injected from the two resin mold injection ports 21e extends in the longitudinal direction of the edgewise coil 13 along the outer periphery of the edgewise coil 13. To flow. Since there is almost no gap between the windings of the edgewise coil 13 and there is sufficient space on the outer periphery of the edgewise coil 13, the resin mold material 25 first wraps around the inner peripheral portion of the edgewise coil 13. The space formed in the outer periphery of the edgewise coil 13 is filled.

This high-pressure resin gives a pressing force to each of the windings 13c, 13d, 13e, 13f,... Of the edgewise coil 13, but each winding 13c, 13d, 13e, 13f,. Are positioned by the upper side of the predetermined width of the ridge 22b, and therefore do not move outward from the tip of the ridge 22b. Further, the windings 13c, 13d, 13e, 13f,... Are parallel to the movable mold.
According to this manufacturing method, as shown in FIG.1 (d), the concave groove 14a of the same width as the protruding item | line 22b is formed in the side surface of the division | segmentation stator 18. As shown in FIG.
Thus, as shown in FIG. 2, when the split stator 18 is combined, as shown in FIG. 11, the gap between the adjacent edgewise coil 13A and the edgewise coil 13B is indicated by W in the figure. Thus, it can be set as W = 0.2 mm or more. Thereby, the insulation between adjacent edgewise coil 13A and edgewise coil 13B can be ensured reliably.

As described above in detail, according to the split stator manufacturing method of the present embodiment, the edgewise mounting is performed on the split stator core 10 inserted through the insulator 12 and inserted into the fixed mold 21 and the movable mold 22. In the split stator manufacturing method in which a resin mold is formed around the coil 13, the outer peripheral surface of the edgewise coil 13 </ b> A and the other edgewise coil 13 </ b> B in the product state (state of the stator 19 shown in FIG. 2). Since a part of the adjacent surface is resin-molded in a state where it is in direct contact with the upper side portion of the ridge 22b formed on the protruding portion 22a of the movable die 22, each winding 13c, 13d of the edgewise coil 13 is formed. , 13e, 13f,... Are respectively pressed, but the windings 13c, 13d, 13e, 13f,. Because it is positioned by the side portions, from the upper portion of the ridge 22b, it does not move outward.
Accordingly, as shown in FIG. 2, when the stator 19 is completed by combining the split stators 18, as shown in FIG. 11, the gap between the adjacent edgewise coils 13A and the edgewise coils 13B is obtained. Can be set to W = 0.2 mm or more, as indicated by W in the figure. Thereby, the insulation between adjacent edgewise coil 13A and edgewise coil 13B can be ensured reliably.

  Further, according to the split stator manufacturing method of the present embodiment, the portion where the edgewise coil 13 is in contact with the convex strip 22b of the movable die 22 is a convex strip at the center position of the side surface of the slot. In addition, when the two resin mold inlets 21e are provided at both ends of the edgewise coil 13, the resin inflow path is the same condition, and therefore the resin mold resin is allowed to flow uniformly into the cavity. Can do. In addition, since the ridge 22b has a trapezoidal cross section, the portion where the resin mold is not formed on the outer periphery of the edgewise coil 13 has only a predetermined width, and thus hardly affects the heat dissipation from the edgewise coil 13. .

Next, a second embodiment will be described. Since the outline of the second embodiment is substantially the same as that of the first embodiment, only the differences will be described in detail, and the description of the same portions will be omitted.
In the first embodiment, the ridge 22b is formed on the surface of the protruding portion 22a. However, in this embodiment, as shown in FIGS. 12 to 14, two ridges 22b are formed on the surface. The ridge slide 30 is slidably held with respect to the protrusion 22a. As shown in FIG. 13, when the movable die 22 is closed, the convex slide 30 is not yet lowered, and after the movable die 22 is closed, as shown in FIG. 30 descends and contacts the side surface of the edgewise coil 13 to position the edgewise coil 13.
According to the second embodiment, only the positioning of the edgewise coil 13 by the ridge slide 30 can be performed as a single action, so that the positioning of the edgewise coil 13 can be performed stably and reliably.

In addition, this invention is not limited to the said embodiment, A part of structure can also be changed suitably and implemented in the range which does not deviate from the meaning of invention.
For example, in the present embodiment, the ridges 22b are linear, but may be two linear at a slightly shifted position. Thereby, there exists an effect which does not interrupt | block the flow of resin for resin molds.
Further, in this embodiment, the purpose is to secure the gap of 0.2 mm or more, but the height of the ridge 22a may be determined according to the necessary gap depending on the voltage used.
Further, although the edgewise coil has been described, it is clear that the present invention can be applied if the coil winding has a round or square cross section if it is formed as a coil.
Moreover, although the present Example demonstrated the case where a thermoplastic resin was used, it is possible to utilize this invention also when a thermosetting resin is used.

4 is a drawing showing a manufacturing procedure of the split stator 18. It is a figure which shows the stator 19 which combined the 18 division | segmentation stators 18 and was shrink-fitted with the outer cylinder 15. FIG. 3 is a cross-sectional view of a split stator 18. FIG. It is a figure which shows the 1st process of the Example of the split stator manufacturing method of this invention. It is a figure which shows the 2nd process of the Example of the split stator manufacturing method of this invention. It is an enlarged view of the protruding item | line 22b formed in one surface of the protrusion part 22a. It is an enlarged view which shows the state which the protruding item | line 22b contact | abuts with the edgewise coil 13. FIG. FIG. 3 is a diagram showing a relationship among a split stator core 10, an insulator 12, and an edgewise coil 13 that are mounted on a fixed mold 21. FIG. 3 is a view showing a state where the edgewise coil 13 is attached to the fixed mold 21. It is a fragmentary sectional view which shows the injection hole of a resin mold. It is a figure which shows the positional relationship of the teeth part 11 and the edgewise coil 13 in the state of FIG. It is a figure which shows the 1st process of 2nd Example. It is a figure which shows the 2nd process of 2nd Example. It is a figure which shows the 3rd process of 2nd Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Split stator core 11 Teeth part 12 Insulator 13 Edgewise coils 13a and 13b Long end 14 Resin mold 14a Groove 18 Split stator 20 Coil gripping block 21 Fixed mold 21a, 21b Slide mold 21d Fixed mold main body 22 Movable mold 22a Projection Ridge 22b ridge 30 ridge slide

Claims (2)

In a split stator manufacturing method in which a resin is molded around a molded coil inserted into a split mold and attached to a split core via an insulator.
Split fixing characterized in that resin molding is performed in a state in which a part of the outer peripheral surface of the molded coil adjacent to another molded coil in a product state is in direct contact with the molding die Child manufacturing method. In the split stator manufacturing method according to claim 1,
The method of manufacturing a split stator, wherein a portion of the molded coil that comes into contact with the molding die is a ridge at a central position of a side surface of the slot.

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