JP2841087B2 - Manufacturing method of connection device for molded motor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial application field] An insulating resin is used for a support frame and a jacket of a stator.
The present invention relates to a method for manufacturing a connection device provided in a mold motor formed by a mold.

[Prior Art] A conventional molded motor having a built-in wiring board will be described with reference to FIGS. 4 (a) and 4 (b). FIG. 4 is a partial side sectional view showing a configuration of a conventional molded motor.

In FIG. 4 (a), a stator iron core (hereinafter referred to as a stator core) 41 is provided with a spool 43 made of an insulating resin.
, The magnet coil 42 is wound around the stator core 41. And a stator armature (hereinafter, referred to as a stator)
A terminal 45 for connecting to a power supply unit is provided on the covering part 44a as a part of the 44, and after assembling the stator 44 around which the magnet core 42 is wound, between the coil ends 42a of the magnet coil 42, and The coil end 42a is electrically connected to the terminal 45, and the magnet coil 42
When the cover 44a of the stator 44 is molded with a resin, the positional relationship between the stator core 41 and the terminal 45 on which the wire is wound is set by the mold.

Here, between the coil ends 42a and between the coil ends 42a
Is generally connected to a wiring pattern (not shown) for connecting between coil ends and a wiring pattern 4 for connecting between coil ends 42a and terminals 45.
A wiring board 46 on which 6a is formed is provided.

Generally, a printed wiring board is provided as the wiring board 46, and the coil end is provided on the wiring board 46.
Soldering is performed between the contact 42a and the contact of the terminal 45.

In FIG. 4B, the power supply lead wire 48 may be directly connected to the coil end 42a of the magnet coil 42 without using a printed wiring board.

In this case, in a subsequent step, when the resin is molded, the temperature of the resin is relatively high, and depending on the case, a solid component or various organic chemicals may be mixed into the resin.

Therefore, it is necessary to use a lead wire 48 which has been coated with a high degree of characteristics that can withstand the above-mentioned temperature and organic chemicals.

[Problem to be Solved by the Invention] In the conventional molded motor configured as described above, the following inconvenience occurs when a printed wiring board is used to connect the coil end and the terminal.

That is, in the conventional molded motor, soldering is performed between the coil ends and the connection with the terminal. For this reason, pretreatment of the soldering portion or insulation treatment after the soldering is required.

In the case of soldering a coil end or a power supply terminal to a printed wiring board, the manufacturing process of the molded motor becomes longer due to the large number of manufacturing steps of the printed wiring board. However, there is an inconvenience that the output of the molded motor is limited by the current capacity of the current conductor.

[Means for Solving the Problems] According to the present invention, a stator in which a magnet coil is wound around a stator core via an insulating spool is provided, and a resin having an insulating property is coated on a covering portion of the stator. In a method of manufacturing a connection device of a molded motor manufactured by using a mold, an electrical connection between each magnet coil wound around a stator core and an electrical connection between a magnet coil and a terminal formed on the stator are provided. It is used for connection, a conductive plate-shaped material is formed into a wiring shape by punching, and a plurality of beams are integrally formed between the wirings. Except for the connection between the terminal and the contact of the terminal, etc., and the engagement with the spool, the pre-molding unit has an arbitrary thickness with an insulating resin. And
The pre-molded current-carrying body is formed into a final shape for use in assembling a molded motor by punching, and at the same time as this forming, unnecessary beams for the circuit configuration of the molded motor are removed by punching. Thus, there is provided a method for manufacturing a connection device for a molded motor, wherein a plurality of connection devices are manufactured.

[Operation] A current-carrying body is pre-molded with an electrically insulating resin between the magnet coils wound around the stator core and between the magnet coils and the terminals formed on the stator. The electrical connection between the coils or between the magnet coils and the terminals simplifies the connection between the magnet coils of the molded motor or between the magnet coils and the terminals, and eliminates the need for insulation treatment during soldering. I do.

Further, by manufacturing a conductive plate material for the current-carrying body of the connection device by press working, the time required for manufacturing the connection device can be reduced.

Further, the current capacity of the conductor of the current-carrying body is increased by pressing the current-carrying body of the connection device by pressing a conductive material plate and using a conductive metal wire.

Also, by molding this current-carrying body with an insulating resin, the current-carrying body of the connection device is made strong.

In addition, by providing a beam together with the current-carrying body between the current-carrying bodies of the connection device, when molding the covering of the stator with an insulating resin, the wiring of the wiring due to the viscosity of the resin or the pressure at the time of injection of the mold is formed. Prevent shape deformation.

Further, a terminal contact is formed integrally with a part of the current-carrying body of the connection device, thereby reducing the number of parts of the molded motor.

Also, when connecting the magnet coil and the connection device,
Conventionally, the work that had been performed by soldering was performed by removing the insulating coating covering the coil end of the magnet coil and simultaneously exposing a part of the current-carrying body of the connection device to form an exposed part in the current-carrying body. It is also possible to connect by so-called wire wrapping, in which a coil end from which an insulating coating portion is peeled is wound around a connection portion formed by bending the portion in a key shape (L shape).

[Example] The present invention will be described based on an example. FIG. 1A is a side sectional view illustrating wiring inside a stator of a molded motor according to the present invention. FIG. 1 (b)
FIG. 2 is a partial longitudinal sectional view as seen from the direction of arrow B in FIG. 1 (a). FIG. 2 (a) is a diagram illustrating a method of manufacturing the connection device. FIG. 2 (b) is an enlarged view of the connection device illustrating the winding connection portion of the connection device of FIG. 2 (a). FIG. 2 (c) is an enlarged view of the connection device as viewed from the direction of arrow C in FIG. 2 (b). FIG. 3 is a view showing another embodiment of the present invention.

1 (a) and 1 (b), a connection device 10 for performing internal wiring is provided inside the stator of the molded motor. The connection device 10 includes an electric conductor 11 for conducting electricity, and a preliminary mold 12 that is provided so as to cover the electric conductor 11 and is made of an insulating resin, and is a coating portion of the connection device 10. Have been. Further, when assembled in the stator, the connecting device 10 is formed in a planar shape so as to fit inside the radial cross section of the stator of the molded motor.

In FIG. 2A, in the present embodiment, the electric conductor 11 is made of a metal plate 11a as a good electric conductor. Further, as the current-carrying body 11, a metal plate 11a (FIG. 2 (a)) having a thickness that can secure a sufficient cross-sectional area to satisfy a current-carrying capacity required for wiring as a motor is used.

The manufacture of the connection device 10 is performed as described later.

First, by pressing, the metal plate 11a is punched into a shape that is slightly larger than the final shape of the current-carrying body 11 and is rough, thereby forming a working material 11b. (FIG. 2 (a)).

Next, the working material 11b is pressed to form a plurality of current-carrying members 11. At this time, in order to maintain a state in which the final shape of the wiring pattern of each conductive body 11 is maintained, that is, to maintain a state in which the interval between the wiring patterns is maintained, each conductive body 11
This beam 11c and the conductor 11
Are pressed together (FIG. 2 (a)).

Next, the current-carrying member 11 provided with the beam 11c is connected to a connecting portion 11d between the current-carrying member 11 and the magnet coil and a connecting portion 11e between the contact of the terminal and the terminal by using an insulating resin.
Preliminary mold 12 is performed except for.

In addition, the thickness of the preliminary mold 12 covering the current-carrying body 11 is such that the deformation of the connection device 10 occurs due to the flow pressure of the resin 13 used for forming the covering portion during molding, which is the final step of the stator manufacturing. In addition, the thickness is set to a thickness sufficient to generate a strength that can be suppressed so as not to affect the performance of the molded motor and the appearance as a product. In addition, even if the outer surface of the preliminary mold 12 is damaged due to contact with the solid component mixed in the resin 13 used in the final step of manufacturing the stator, the damage does not reach the electric conductor 11. Make it thick enough.

Then, a beam 11c provided between the current-carrying members 11 is punched out by punching or the like to form a hole 14 corresponding to the beam 11c to ensure insulation of the current-carrying members 11. This opening 14
During molding, which is the final process of stator production, resin 13
Penetrate into the opening 14 to ensure insulation between the current-carrying bodies 11.

At the same time, the notch 15 for connecting the coil end of the magnet coil to the current-carrying member 11 and the notch 15 for the short-circuit wire for changing the wiring connection depending on the model of the motor, and the connection The notch 17, which is an engaging portion of the spool 16 with the engaging portion 16a for fixing the device 10, can be formed at the same time (FIG. 2 (a)).

In FIG. 2 (a), the ones indicated by dashed lines are connected in a chained state so that a plurality of connecting devices can be handled together from the manufacturing stage. Beam 18.

By providing the connecting beam 18, in the step of punching the outer diameter of the current-carrying body 11, an elongated plate material can be used as a material plate. That is, stepwise punching by one punching die is enabled, and it is possible to handle a plurality of current-carrying members 11 simultaneously in a subsequent step (for example, a punching step or a molding step using a resin).

2 (b) and 2 (c), the electric conductor 11
The shape of the connection part with the magnet coil is key-shaped (L-shaped)
Thus, the magnet coil can be connected to the connection portion of the current-carrying member 11 by a wire wrapping method.

Further, as a method of connecting the internal wiring of the stator of the molded motor and an apparatus using the method, the following other methods can be considered.

3 (a) and 3 (b), an annular substrate 33 is formed of an insulating resin. Then, a hole 32 into which the metal wire 31 can be inserted is provided at an arbitrary position on the substrate 33.

This hole 32, when the metal wire 31 inserted into the hole 32, when forming the coating portion of the stator performed in a later step, against the flow pressure of the resin mold and the force drawn by the flow of the magnet coil, It is provided in such a size as to generate a tightening force enough to hold the metal wire 31 sufficiently.

By using the metal wire 31 as an electric conductor, the connection between the magnet coils, and the connection between the magnet coil and the terminal, by performing so-called wire wrapping,
The need for solder connection can be eliminated.

Furthermore, it is needless to say that the arrangement of the metal wires can be freely changed according to the type of the molded motor by providing a plurality of the holes at random.

Further, in the present embodiment, an example in which a metal plate is used for the current-carrying body has been described, but the present invention is not limited to this.
A plate formed from a material having the same or higher conduction characteristics as the conductive metal may be used.

[Effects of the Invention] By using a molded motor having the connecting device configured as described above, the manufacturing process of the connecting device can be simplified, and the manufacturing time of the connecting device can be significantly shortened. The current capacity of the conductor of the device is increased, the restriction is greatly relaxed compared with the conventional motor using a printed wiring board for the connection device, and the usable output of the molded motor can be increased.

Note that the wiring pattern of the current-carrying body of the connection device can be easily changed by exchanging a punching die, thereby providing a connection device compatible with high-mix low-volume production.

And since the board | substrate was formed by previously providing a hole for inserting an electric conductor using an insulating resin as a material of the metal wire, it is possible to mount the metal wire as the electric conductor very easily.

Furthermore, by using a metal wire as an electric conductor, soldering is not required between the magnet coils and between the magnet coils and the terminals, thereby enabling automatic connection using a robot.

[Brief description of the drawings]

FIG. 1 (a) is a side sectional view for explaining a stator internal wiring of a molded motor according to the present invention. FIG. 1 (b) is a partial longitudinal sectional view as viewed from the direction of arrow B in FIG. 1 (a). FIG. 2 (a) is a diagram illustrating a method of manufacturing the connection device. FIG. 2 (b) is an enlarged view of the connection device illustrating the winding connection portion of the connection device of FIG. 2 (a). FIG. 2 (c) is an enlarged view of the connection device as viewed from the direction of arrow C in FIG. 2 (b). FIG. 3 is a view showing another embodiment of the present invention. FIG. 4 is a partial side sectional view showing a configuration of a conventional molded motor. 10 Connection device 11 Conductor 11a Metal plate 11b Processing material 11c Beam 11d, 11e Connection 12 Preliminary mold 13 Resin 14 Opening 15, 17 ... Notch 16 ... Spool 16a ... Locking part 18 ... Connecting beam 31 ... Metal wire 32 ... Hole 33 ... Board

Claims (1)

(57) [Claims] 1. A stator having a stator core on which a magnet coil is wound via an insulating spool, and a molded portion formed on a covering portion of the stator by using an insulating resin. In a method of manufacturing a connection device for a molded motor, the method is used for electrical connection between each magnet coil wound around a stator core and electrical connection between a magnet coil and a terminal formed on a stator, and is performed by punching. A conductive plate formed of a conductive plate-like material in a wiring shape, and a plurality of beams integrally formed between the wirings; and a connecting portion between the coil end and a contact of the terminal or the like. And, except for the engaging portion with the spool, preliminarily molded with an arbitrary thickness using a resin having an insulating property. The current-carrying body is formed by punching into the final shape used when assembling the molded motor. At the same time as this molding, beams unnecessary for the circuit configuration of the molded motor are removed by punching, and A method for manufacturing a connection device for a molded motor, characterized by manufacturing the connection device of (1).