JP2022182193A - Method for manufacturing stator - Google Patents

Abstract

To provide a method for manufacturing a stator which can easily manufacture a stator mounting an electronic component on a circuit board.SOLUTION: A method for manufacturing a stator which is arranged so as to face a rotor rotating about a central axis includes: a first step of mounting an annular stator cover on an insulating substrate having a circuit pattern, mounting a stator core inside the stator cover of the substrate, mounting a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin into the stator cover; a third step of heating and curing the thermosetting resin, and thereby fixing the stator cover, the stator core and the coil onto the substrate; a fourth step of mounting the electronic component onto the substrate, and connecting the electronic component to the circuit pattern; and a fifth step of cutting a mounting region where the stator cover of the substrate, the stator core, the coil and the electronic component are mounted from a non-mounting region around the substrate mounting region.SELECTED DRAWING: Figure 5

Description

TECHNICAL FIELD The present invention relates to a method of manufacturing a stator arranged to face a rotor that rotates about a central axis.

2. Description of the Related Art Conventionally, a motor is known that has a stator arranged opposite to a rotor that rotates about a central axis.

For example, Patent Literature 1 discloses a stator integrally formed of molded resin in a state in which nine core members each having windings wound around an insulator covering the stator core leaving the tooth portions are annularly connected. An axial gap motor is disclosed. The stator of Patent Document 1 has a shaft insertion hole into which the shaft is inserted, a pair of bearing housing holes continuously formed in the shaft insertion hole and into which the bearings are respectively housed, and a substrate arrangement stepped portion in which the circuit board is arranged. and a pair of lid-fitting stepped portions to which the bracket lids are respectively fitted are integrally formed of molded resin.

JP 2012-182862 A

However, in Patent Document 1, there is no description of electronic components mounted on a circuit board, and no specific description of a manufacturing method of the stator. There is room for improvement.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing a stator that can easily manufacture a stator having electronic components mounted on a circuit board.

A method of manufacturing a stator according to the present invention is a method of manufacturing a stator that is arranged to face a rotor that rotates about a central axis, comprising: mounting an annular stator cover on an insulating substrate having a circuit pattern; a first step of mounting a stator core inside the stator cover, mounting a coil around the stator core, and connecting the coil to the circuit pattern; and injecting liquid thermosetting resin into the inside of the stator cover. a second step of heating and curing the thermosetting resin to fix the stator cover, the stator core, and the coil on the substrate; and mounting an electronic component on the substrate. a fourth step of connecting to the circuit pattern; and cutting a mounting area of the board on which the stator cover, the stator core, the coil and the electronic component are mounted from a non-mounting area surrounding the mounting area of the board. and a fifth step.

ADVANTAGE OF THE INVENTION According to this invention, the stator which mounts an electronic component on a circuit board can be manufactured easily.

1 is a perspective view of an axial motor with a stator according to an embodiment of the invention; FIG. 1 is an exploded perspective view of an axial motor having a stator according to an embodiment of the invention; FIG. 1 is a perspective view of a stator coil assembly of a stator according to an embodiment of the invention; FIG. 4 is a perspective view of a stator cover of the stator according to the embodiment of the invention; FIG. It is a flow chart showing a manufacturing method of a stator concerning an embodiment of the present invention. 1 is an exploded perspective view showing a first step of a method for manufacturing a stator according to an embodiment of the invention; FIG. It is a perspective view which shows the 1st process of the manufacturing method of the stator which concerns on embodiment of this invention. It is a perspective view which shows the 2nd process and 3rd process of the manufacturing method of the stator which concerns on embodiment of this invention. FIG. 5 is a perspective view showing a fourth step of the stator manufacturing method according to the embodiment of the present invention; FIG. 11 is a perspective view showing a fifth step of the stator manufacturing method according to the embodiment of the present invention;

Hereinafter, an axial motor and a stator including a stator according to embodiments of the present invention will be described with reference to the drawings. The scope of the present invention is not limited to the following embodiments, and can be arbitrarily changed within the scope of the technical idea of the present invention. Also, in the drawings below, the scale, number, etc. of each structure may be different from the scale, number, etc. of the actual structure in order to make each configuration easier to understand.

<Configuration of axial motor>
A configuration of an axial motor 100 including a stator 2 according to an embodiment of the invention will be described in detail with reference to FIGS. 1 and 2. FIG.

The axial motor 100 has a rotor 1 that is rotationally driven, a stator 2 that rotates the rotor 1, and bearings 15 .

The rotor 1 has a shaft 11 , a yoke 12 , magnets 13 , a yoke 14 and an encoder disk 16 .

The shaft 11 passes through the yoke 12 , the encoder disk 16 , the stator coil assembly 21 and the front cover 23 , and is a rotating shaft (central shaft) that rotates the rotor 1 relative to the stator 2 .

The yoke 12 is arranged to face one surface (upper surface in FIG. 2) of the stator coil assembly 21 in the rotation axis direction, and is attached to the shaft 11 .

The magnets 13 are circumferentially arranged on the surface of the yoke 12 facing the stator coil assembly 21 and circumferentially arranged on the surface of the yoke 14 facing the stator coil assembly 21 .

The yoke 14 is arranged to face the other surface (lower surface in FIG. 2) of the stator coil assembly 21 in the rotation axis direction, and is attached to the shaft 11 .

The encoder disk 16 is provided on the surface of the stator coil assembly 21 facing the yoke 14 .

The stator 2 is arranged to face the rotor 1 in the rotation axis direction, and includes a stator coil assembly 21 , a front cover 23 and a rear cover 24 .

A stator coil assembly 21 is provided between the yokes 12 and 14 . The stator coil assembly 21 is arranged to face the rotor 1 in the central axis direction. Details of the configuration of the stator coil assembly 21 will be described later.

The front cover 23 accommodates the yoke 12 and fastens and fixes the stator coil assembly 21 with front bolts 25 .

The rear cover 24 accommodates the yoke 14 and fastens and fixes the stator coil assembly 21 with rear bolts 26 .

The bearings 15 are provided on the side of the stator coil assembly 21 facing the yoke 12 and the side facing the yoke 14 , and rotatably support the shaft 11 .

<Structure of stator coil assembly>
A configuration of the stator coil assembly 21 of the stator 2 according to the embodiment of the invention will be described in detail with reference to FIGS. 2 to 4. FIG.

The stator coil assembly 21 has a stator cover 211, a substrate 212, a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC 216, a power signal terminal set 217, and a bearing holder 219. .

Stator cover 211 is annular. The stator cover 211 is provided with recessed grooves 211A at intervals of 90 degrees in the circumferential direction. The stator cover 211 is provided with fastening holes 211B between the recessed grooves 211A into which front bolts 25 for fastening the front cover 23 and rear bolts 26 for fastening the rear cover 24 are press-fitted.

The substrate 212 is made of an insulating material, and includes a connecting portion 212A and a main substrate 212C. A conductive circuit pattern (not shown) is formed by printing on the main board 212C, and a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC 216, a power signal terminal set 217, and a bearing holder are connected to this circuit pattern. 219 is implemented.

The stator core 213 is radially mounted around the shaft 11 inside the stator cover 211 of the main substrate 212C. A plurality of stator cores 213 are mounted on the main board 212C at intervals along the circumferential direction.

The coil 214 is mounted around the stator core 213 and connected to the circuit pattern of the main board 212C. Note that the number of stator cores 213 and coils 214 is not limited to the number shown in FIG.

The magnetic sensor 215 is mounted at a position farther from the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21 on the main substrate 212C. The magnetic sensor 215 is surface-mounted on the main substrate 212C by SMT (Surface Mount Technology). The magnetic sensor 215 detects the magnetic field of the coil 214 and outputs an electric signal corresponding to the detection result to the connector 217A through the circuit pattern of the main substrate 212C.

The encoder sensor IC 216 is mounted at a position closer to the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and stator coil assembly 21 on the main substrate 212C. The encoder sensor IC 216 is surface-mounted on the main substrate 212C by SMT. The encoder sensor IC 216 detects the position of the rotor 1 by reading the encoder disk 16, and outputs an electric signal according to the detection result to the connector 217A through the circuit pattern of the main board 212C.

The power signal terminal set 217 is composed of a connector 217A and a power connector 217B. The power signal terminal set 217 is surface-mounted on the main substrate 212C by SMT.

The connector 217A is mounted on the main board 212C. The connector 217A has a signal terminal (not shown) connected to the circuit pattern of the main substrate 212C, and is connected to the magnetic sensor 215 and the encoder sensor IC 216 via the circuit pattern of the main substrate 212C. The connector 217A is fitted with a mating connector (not shown) to output an electric signal output from the magnetic sensor 215 or the encoder sensor IC 216 to the outside.

The power connector 217B is mounted on the main board 212C. The power connector 217B has a power terminal (not shown) connected to the circuit pattern of the main substrate 212C, and is connected to the coil 214 via the circuit pattern of the main substrate 212C. The power connector 217B is fitted with a mating connector (not shown) to supply power to the coil 214 .

The bearing holder 219 is attached to the main substrate 212C. The bearing holder 219 holds the bearing 15 while the shaft 11 is inserted therethrough.

<Manufacturing method of stator>
A method of manufacturing the stator 2 according to the embodiment of the present invention will be described in detail with reference to FIGS. 2 and 5 to 10. FIG. 7, illustration of the tooling frame board 212B is omitted.

First, the substrate 212 shown in FIG. 6 is prepared, which has a connection portion 212A that connects the main substrate 212C and the tooling frame substrate 212B at the slit portion 212D.

Here, the substrate 212 is composed of a connecting portion 212A, a tooling frame substrate 212B, and a main substrate 212C.

The main board 212</b>C has a fitting hole 212</b>F that passes through the board 212 in the plate thickness direction and into which the stator core 213 is fitted. The fitting holes 212F are provided radially around the central axis through which the shaft 11 is inserted. Between the tooling frame board 212B and the main board 212C, a slit portion 212D is provided that penetrates the board 212 in the thickness direction.

Next, as shown in FIG. 6, an annular stator cover 211 is mounted on an insulating main board 212C having a circuit pattern, and a stator core 213 is mounted inside the stator cover 211 of the main board 212C. , and connect the coil 214 to the circuit pattern of the main substrate 212C (first step) (S1). As a result, the state shown in FIG. 7 is obtained.

In the first step, the connecting portion 212A and the groove portion 211A provided in the stator cover 211 are engaged with each other, and the stator cover 211 is inserted into the slit portion 212D to mount the stator cover 211 on the main board 212C. Thereby, the stator cover 211 can be easily positioned on the substrate 212 .

Furthermore, in the first step, the stator core 213 is mounted on the main board 212C by fitting the stator core 213 into the fitting hole 212F. Thereby, the stator core 213 can be easily positioned with respect to the main board 212C.

Next, as shown in FIG. 8, a liquid thermosetting resin is injected into the gap between the stator cover 211 inside the stator cover 211 and the coil 214 (second step) (S2).

Next, the resin portion 218 is formed by heating and hardening the thermosetting resin, and the stator cover 211, the stator core 213 and the coil 214 are fixed on the main substrate 212C (third step) (S3). Before mounting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 on the main board 212C, the thermosetting resin is heated to form the resin portion 218, whereby the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted. Damage due to heating of the terminal set 217 can be prevented.

Next, as shown in FIG. 9, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217, which are electronic components, are surface-mounted on the main substrate 212C by turning the state shown in FIG. 8 upside down. It is connected to the circuit pattern of the main substrate 212C (fourth step) (S4). At this time, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main substrate 212C by an automatic machine such as a chip mounter. Also, the tooling frame board 212B arranged around the main board 212C is supported by the automatic machine when it is transported in the automatic machine. By providing the tooling frame substrate 212B, the substrate 212 can be easily positioned on the belt conveyor in the automatic machine.

Next, as shown in FIG. 10, by cutting the connection portion 212A, the mounting area where the stator cover 211, the stator core 213, the coil 214, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted. A certain main board 212C is cut from the tooling frame board 212B, which is a non-mounting area around the main board 212C (fifth step) (S5). Since the main board 212C and the tooling frame board 212B can be cut by cutting the connecting portion 212A, the main board 212C and the tooling frame board 212B can be easily cut.

By cutting the connecting portion 212A, a burr 212E remains on the tooling frame substrate 212B, a burr also remains on the cross section 212G of the connecting portion 212A of the stator coil assembly 21, and the cross section 212G becomes a fractured surface.

Using the stator coil assembly 21 manufactured by the manufacturing method described above, the stator 2 is manufactured so as to have the arrangement shown in FIG.

As described above, according to the present embodiment, after the third step of fixing the stator cover 211, the stator core 213, and the coil 214 onto the main board 212C by heating and hardening the thermosetting resin, the main board 212C is mounted on the main board 212C. By performing the fourth step of mounting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 on and connecting them to the circuit pattern, the magnetic sensor 215, the encoder sensor IC 216, and the magnetic sensor 215, the encoder sensor IC 216, and the The power signal terminal set 217 can be prevented from being heated at a high temperature, and the stator coil assembly 21 in which the magnetic sensor 215, the encoder sensor IC 216 and the power signal terminal set 217 are mounted on the main substrate 212C can be easily manufactured. .

Further, according to the present embodiment, in the fourth step, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main substrate 212C. The operation of connecting the encoder sensor IC 216 and the power signal terminal set 217 to the circuit pattern of the main board 212C can be automated by an automated SMT production line, which can significantly reduce the number of man-hours and reduce the manufacturing cost. be able to.

The above-described embodiments should be considered illustrative and not restrictive in all respects. The scope of the present invention is indicated by the scope of the claims rather than the above-described embodiments, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims.

Specifically, although the stator coil assembly 21 is provided in the axial flux motor 100 in the above embodiment, the stator coil assembly 21 may be provided in a motor other than the axial flux motor.

Further, although the stator core 213 is provided in the above embodiment, the present invention is not limited to this, and the stator core 213 may not be provided.

In the above embodiment, the electronic components such as the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main substrate 212C. It may be implemented by an implementation method other than implementation.

In the above embodiment, the magnetic sensor 215, the encoder sensor IC 216 and the power signal terminal set 217 are surface-mounted on the main substrate 212C by an automatic machine. 217 may be manually mounted on the main substrate 212C.

In the above embodiment, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted on the main substrate 212C as electronic components. can do.

In the above embodiment, the magnetic sensor 215 is mounted at a position farther from the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21, and the shaft 11 (central axis ), the magnetic sensor and the encoder can be mounted at arbitrary positions on the main substrate.

1 Rotor 2 Stator 11 Shaft 12 Yoke 13 Magnet 14 Yoke 15 Bearing 16 Encoder Disk 21 Stator Coil Assembly 23 Front Cover 24 Rear Cover 25 Front Bolt 26 Rear Bolt 100 Axial Motor 211 Stator Cover 211A Groove Part 211B Fastening Hole 212 Board 212A Connection Part 212B Tooling Frame substrate 212C Main substrate 212D Slit portion 212E Burr 212F Fitting hole 212G Section 213 Stator core 214 Coil 215 Magnetic sensor 216 Encoder 217 Power signal terminal set 217A Connector 217B Power connector 218 Resin portion 219 Bearing holder

Claims (10)

A method for manufacturing a stator arranged to face a rotor that rotates about a central axis, comprising:
An annular stator cover is mounted on an insulating substrate having a circuit pattern, a stator core is mounted inside the stator cover of the substrate, a coil is mounted around the stator core, and the coil is connected to the circuit pattern. a first step;
a second step of injecting liquid thermosetting resin into the stator cover;
a third step of heating and curing the thermosetting resin to fix the stator cover, the stator core, and the coil on the substrate;
a fourth step of mounting an electronic component on the substrate and connecting it to the circuit pattern;
a fifth step of cutting a mounting region of the substrate where the stator cover, the stator core, the coil and the electronic component are mounted from a non-mounting region surrounding the mounting region of the substrate;
A method for manufacturing a stator, comprising: The fourth step is
surface-mounting the electronic component on the substrate;
2. The method of manufacturing a stator according to claim 1, wherein: A step of preparing the substrate having a connecting portion connecting the mounting region and the non-mounting region in a slit portion penetrating in the plate thickness direction provided between the mounting region and the non-mounting region of the substrate. have
3. The method of manufacturing a stator according to claim 1, wherein: The first step is
The stator cover is mounted on the substrate by engaging the coupling portion with a groove provided in the stator cover and inserting the stator cover into the slit portion.
4. The method of manufacturing a stator according to claim 3, wherein: The fifth step is
cutting the mounting region from the non-mounting region by cutting the connecting portion;
5. The method of manufacturing a stator according to claim 3 or 4, characterized in that: The fourth step is
A connector having a power terminal and a signal terminal as the electronic component is mounted on the substrate, and the power terminal and the signal terminal are connected to the circuit pattern.
6. The method of manufacturing a stator according to any one of claims 1 to 5, characterized in that: The fourth step is
A sensor that detects the position of the rotor as the electronic component is mounted on the substrate, and a terminal portion of the sensor is connected to the circuit pattern.
7. The method of manufacturing a stator according to any one of claims 1 to 6, characterized in that: The first step is
mounting the stator core on the substrate by fitting the stator core into a fitting hole provided in the substrate and penetrating in the plate thickness direction;
8. The method of manufacturing a stator according to any one of claims 1 to 7, characterized in that: The stator is
arranged opposite to the rotor in the central axis direction,
9. The method of manufacturing a stator according to any one of claims 1 to 8, characterized in that: The fourth step is
mounting the electronic component at a position closer to or farther from the central axis than the stator core in the radial direction of the stator;
10. The method of manufacturing a stator according to any one of claims 1 to 9, characterized in that:

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