JP3815042B2 - Manufacturing method of stator of rotating electric machine - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method of manufacturing a stator of a rotating electrical machine.
[0002]
[Prior art]
Conventionally, in a stator of a small DC motor such as a starter motor, a field coil (hereinafter referred to as a main coil) is used to prevent mechanical damage (for example, damage to a starter pinion gear) due to abnormal high-speed rotation during no-load operation. In addition, there is known a structure including a multi-turn coil provided with an auxiliary shunt coil (hereinafter referred to as a shunt coil) (see, for example, JP-A-63-154055).
[0003]
[Problems to be solved by the invention]
However, the conventional multi-turn coil structure has a problem due to its configuration.
The conventional processes and problems will be described below.
First, winding bobbins of the same number as the number of poles of the stator are prepared in advance.
Subsequently, the main coil and the shunt coil are sequentially wound around the same bobbin using a winding device. At this time, it is necessary to draw out the ends (winding start and winding end) of each winding to the outside of the bobbin. The number of terminals is 2 (main shunt) × 2 (start of winding and end of winding) × N = 4N, where N is the number of poles of the stator.
Subsequently, the bobbin after winding is attached to a single pole core (a pole core before being fixed to the yoke), and the pole core to which the bobbin is attached is fixed to the yoke by screwing or caulking. When winding on a bobbin in this way (indirect winding), it is necessary to separate the bobbin winding process from the bobbin mounting process. It is necessary to keep.
[0004]
Then, in order to connect the terminal of each coil | winding and to comprise a predetermined electric circuit, each terminal is electrically connected for every predetermined location using a connection bar.
In general, since the shunt coil uses an extra fine wire with respect to the main coil, the certainty is important when connecting to the connection bar. For this reason, it is extremely important to reduce the number of connection points. However, if winding is performed using a bobbin, the shunt coil must be divided into the number of poles, and thus the number of connection points cannot be reduced. For this reason, the connection work between the shunt coil and the connection bar becomes complicated, and the work space for connecting each of the main coil and the shunt coil wound around each bobbin with a jumper becomes extremely small. As a result, the difficulty of the wiring work is increased, and automation is difficult and relies on manual work, so that there is a problem that reliability and productivity are lowered.
In addition, since it takes much time to reliably inspect the performance of each of the main coil and the shunt coil, it is difficult to perform an electrical inspection method for the finished product.
[0005]
  The above problem is a problem derived from the indirect winding of the shunt coil and the main coil in advance on the bobbin. As a means for solving this, a method of directly winding each coil around the pole core is conceivable. However, the specific winding method has not been realized. The reason is that a technical means for solving the problem that occurs when each coil is directly wound around the pole core has not yet been established.
  The problems in winding each coil directly on the pole core are listed.
(1) In the winding sequence of the shunt coil and the main coil, the optimal sequence is unclear in terms of winding efficiency and terminal processability.
(2) The method for preventing breakage and scratches of the connecting wire between the shunt coil poles is unknown.
(3) In terminal processing, the configuration that achieves both reduction in joint sites and workability in connection work is unknown.
(4) The product configuration, process, and inspection method optimal for mass production are unknown.
  The present invention has been made based on the above circumstances, and its purpose is to improve the reliability and productivity of a stator including a main coil and a shunt coil.,andThe electrical inspection of electrical circuits can be performed reliablyManufacturing method of stator of rotating electric machineIs to provide.
[0006]
[Means for Solving the Problems]
(Means of Claim 1)
In a state where the pole core is fixed to the yoke in advance, a single shunt coil is sequentially wound around at least two pole cores, and then the main coil is wound around a plurality of pole cores. Note that the shunt coil may be wound around at least two pole cores even when there are four or more pole cores. Of course, it goes without saying that all the pole cores may be wound.
In this case, since the shunt coil thinner than the main coil is wound before the main coil, the connecting wire of the shunt coil is firmly held between the main coil wound on the upper layer of the shunt coil and the inner wall of the yoke. It becomes a structure. Thereby, disconnection of the shunt coil which carries out the multilayer winding of one extra fine wire can be prevented, and the stator excellent in vibration resistance can be provided. Further, by winding the shunt coil and the main coil directly on the pole core that is fixed to the yoke in advance, the working efficiency is high, automation is easy, and an inexpensive stator can be provided.
[0010]
  Further, after winding the shunt coil and the main coil around the pole core, the failure of the electric circuit is detected by the following procedure.
  First, after electrically connecting the main terminal to the main coil, the insulation state between the main coil and the yoke is inspected,
  continue,Held by terminal holding meansAfter electrically connecting the shunt coil to the shunt terminal, inspect the insulation state between the shunt coil and the yoke,
  Subsequently, after electrically connecting the-side shunt terminal to the yoke, the insulation state between the main coil and the yoke is inspected again,
  Subsequently, after the + side shunt terminal and the + side main terminal are electrically connected to the terminal connecting means, a short circuit inspection between the main coil and the shunt coil, and the resistance value of the main coil and the resistance value of the shunt coil Inspect.
  By performing each inspection according to the above procedure, it is possible to reliably detect defects related to the ground, short circuit, and resistance value of the main coil and shunt coil, so high quality and high reliabilitystatorCan provide.
  Needless to say, the terminal holding means insulates between the + side shunt terminal and the − side shunt terminal and between the + side shunt terminal and the yoke. That is, the terminal holding means is preferably formed of an insulating material such as a thermoplastic resin, as long as the surface is insulated even with a conductive material.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
FIG. 1 is an upper plan view seen from the axial direction of the stator.
The stator 1 of the present embodiment is provided in a DC motor such as a starter motor, for example. Each component described below [a yoke 2, a pole core 3 (3A to 3D), a shunt coil 4, a main coil 5, a bushing. Insulation 6, shunt terminal 7 (7A, 7B), main terminal 8 (8A, 8B), connection bar 9, lead wire 10, brush 11, etc. In addition, since structures other than the stator 1 of the DC motor are extremely known, the description thereof is omitted.
[0012]
a) York 2
It is formed in a cylindrical shape with a ferromagnetic material such as iron or steel (see FIGS. 4 and 5).
b) Pole core 3
As shown in FIG. 4, a predetermined number (four in this embodiment) of pole cores 3 are fixed to the inner wall of the yoke 2, and the pole cores 3 are arranged at equal intervals in the circumferential direction of the yoke 2. The pole core 3 includes a core portion 3a and a flange portion 3b (magnetic pole piece), and a shunt coil 4 and a main coil 5 are wound around the core portion 3a.
c) Shunt coil 4
The shunt coil 4 uses a covered electric wire in which one electric wire is covered with an insulating film, and the covered electric wire is continuously wound around each pole core 3 sequentially (see FIG. 3).
d) Main coil 5
The main coil 5 uses a covered electric wire in which a plurality of electric wires are bundled and covered with an insulating coating, and the covered electric wire is wound around the upper layer of the shunt coil 4 of each pole core 3 (see FIG. 3).
[0013]
e) Bushing insulation 6 (hereinafter abbreviated as insulation 6)
An annular component that holds the shunt terminal 7 and is attached to the inner periphery of one open end of the yoke 2. As shown in FIG. 6, the insulation 6 includes a main coil lead-out portion 6 a for drawing out the lead-out wire of the main coil 5 on the outer diameter side, and a shunt coil lead-out portion for drawing out the lead-out wire of the shunt coil 4. 6b is formed. In addition, as shown to FIGS. 7-9, you may provide the taper part 6c for each coil extraction | drawer part 6a, 6b for guiding the extraction | drawer line of each coil 4 and 5, respectively.
The insulation 6 is preferably made of an insulating material, particularly a thermoplastic resin, in order to hold the + side shunt terminal 7A and the − side shunt terminal 7B in a state of being attached to the yoke 2. However, even a conductive material can be used if the surface is insulated.
[0014]
f) + side shunt terminal 7A
10 is a component that is connected to the lead wire (terminal) of the shunt coil 4 drawn from one coil lead portion 6b of the insulation 6 and performs electrical connection with the connection bar 9. As shown in FIG. The portion 70 is provided with a connection means to the insulation 6 (two fitting holes 7a in FIG. 10), a joint joint portion 7b to the connection bar 9, and a joint joint portion 7c to the shunt coil 4. The + side shunt terminal 7A is made of a conductive material such as iron or copper (copper is optimal), and is preferably subjected to plating (optimum tin plating) in order to improve weldability with the connection bar 9. In addition, although the joint joint part 7c with the shunt coil 4 shown in FIG. 10 is opened in substantially V shape, you may provide in flat form as shown in FIG. Further, as shown in FIG. 12, in addition to the joint joint portion 7c, a temporary holding joint portion 7d may be provided.
[0015]
g)-side shunt terminal 7B
13 is a component that is connected to the lead wire (terminal) of the shunt coil 4 drawn from the other coil lead portion 6b of the insulation 6 and makes electrical connection with the yoke 2. As shown in FIG. 71 is provided with a connection means to the insulation 6 (two fitting holes 7a in FIG. 13), a joint joint portion 7e to the yoke 2, and a joint joint portion 7f to the shunt coil 4. The-side shunt terminal 7B is made of a conductive material such as iron or copper (copper is optimal), and is preferably subjected to a plating process (tin plating is optimal) in order to improve weldability with the yoke 2.
In addition, the plate | board thickness of each shunt terminal 7A, 7B of + side and-side is good to set it as the wire diameter of the shunt coil 4 x (0.6-0.9).
[0016]
h) + side main terminal 8A
These are parts provided on the lead wires of the main coil 5 drawn from the two coil lead portions 6a of the insulation 6 to make electrical connection with the connection bar 9, and made of a conductive material such as iron or copper. It is formed in a substantially U shape (see FIG. 33).
i)-side main terminal 8B
It is a component that is provided on the lead wire of the main coil 5 drawn from the other two coil lead portions 6a of the insulation 6 and makes electrical connection with the brush 11, and is made of a conductive material such as iron or copper. It is formed in a substantially U shape (see FIG. 33).
[0017]
j) Connection bar 9
This is a terminal connecting component for electrically connecting the two + side main terminals 8A and the + side shunt terminal 7A (see FIGS. 1 and 3).
The connection bar 9 is made of a conductive material such as iron or copper (copper is optimal), and is preferably subjected to plating (optimum tin plating) in order to improve weldability with the terminals 8A and 7A.
k) Lead wire 10
A lead wire 10 for supplying electric energy from an unillustrated battery to the electric circuit of the stator 1, one end connected to the positive electrode of the battery and the other end connected to the connection bar 9 (see FIG. 1 and FIG. 1). (See FIG. 3).
l) Brush 11
A current path between the stator 1 and the rotor is formed by sliding the commutator surface of the rotor (not shown).
[0018]
Next, the electric circuit of the stator 1 (each connection structure of the shunt coil 4 and the main coil 5) will be described with reference to FIG. FIG. 3 is an example of a development view when the stator 1 is viewed from the inner diameter side.
Wiring structure of shunt coil 4. Lead wire 10 → connection bar 9 → + side shunt terminal 7A → lead wire 4a of shunt coil 4 → winding to left rotation with respect to first pole core 3A → crossover wire 4b → second wire Winding clockwise to the pole core 3B → crossover wire 4c → winding to the left rotation to the third pole core 3C → crossover wire 4d → winding clockwise to the fourth pole core 3D → lead wire of the shunt coil 4 4e →-side shunt terminal 7B → yoke 2 is grounded.
Connection structure of the main coil 5: lead wire 10 → connection bar 9 → positive side main terminal 8A (2 pieces) → winding and second and fourth windings to the left with respect to the first and third pole cores 3A and 3C Winding clockwise with respect to the pole cores 3B and 3D → the main terminal 8B (2 pieces) → the brush 11 → to the rotor via the commutator.
[0019]
Then, the processing apparatus for manufacturing the stator 1 of a present Example is demonstrated.
The machining apparatus includes a pallet 12 (see FIG. 14) for loading a workpiece W (workpiece) and transporting between each process, a winding machine 13 (see FIG. 15) of the shunt coil 4, and winding of the main coil 5. It is comprised from the wire machine 14 (refer FIG. 17), the terminal processing apparatus 15 (refer FIG. 19) of the shunt coil 4, etc.
a) Pallet 12
As shown in FIG. 14, the pallet 12 includes a base part 120, a work holding part 121, and a terminal holding means 122 for the shunt coil 4.
The base portion 120 functions as a guide portion when moving on the production line (see FIG. 21).
[0020]
The work holding part 121 is provided in a cylindrical shape on the base part 120, and receives the other opening part side (lower end part in FIG. 2) of the yoke 2 to hold the yoke 2 (work W) inside the cylinder. To do.
The terminal holding means 122 holds the lead wire (winding start line and winding end line) of the shunt coil 4 wound around the pole core 3, and the base portion 120 in the vicinity where the lead wire of the shunt coil 4 is drawn. Two places are provided on the top. The terminal holding means 122 may be a mechanism that holds (holds) the lead line by using elasticity, for example. Further, the terminal holding means 122 is arranged so that the lead wire of the shunt coil 4 being held does not obstruct the work in each process, and the upper opening of the work W (yoke 2) held by the work holding part 121. It is better to provide it at a lower position.
[0021]
b) Winding machine 13 for the shunt coil 4
As shown in FIG. 15, the winding machine 13 includes a tension generator 130, a winding device 131, a nozzle part 132, a terminal processing mechanism 133, a pallet moving mechanism 134, a winding pack 135, and the like.
The tension generator 130 can generate a predetermined tension on the electric wire D.
The winding device 131 includes a path (not shown) for supplying the electric wire D to the nozzle portion 132, a flange portion 3b of the pole core 3 and a cam mechanism (not shown) that is substantially similar to the flange portion 3b. It rotates at high speed while following a trajectory that roughly follows the rotation.
As shown in FIG. 16, the nozzle portion 132 includes one winding nozzle 136 on the side surface of the nozzle portion 132, and the nozzle portion 132 rotates on the inner peripheral side of the pole core 3, whereas the winding nozzle When 136 supplies the electric wire D to the magnetic pole part of the pole core 3, the efficiency at the time of winding can be raised.
[0022]
The terminal processing mechanism 133 is a mechanism for holding the terminal (winding start line and winding end line) of the shunt coil 4 on the terminal holding means 122 of the pallet 12, and each operation of raising, lowering, and rotating in addition to holding the terminal. Is possible.
The pallet moving mechanism 134 has a function of rotating the pallet 12 to a predetermined position, and a function of raising and lowering during winding processing and terminal processing.
The winding pack 135 is a wire supply pack, and houses the wire D for the shunt coil 4 therein.
The winding machine 13 determines the relative positions of the pole cores 3 and the winding nozzle 136 with respect to the axis of the yoke 2 in cooperation with the winding device 131 and the pallet moving mechanism 134, as shown in FIG. The nozzle portion 132 can be wound around a predetermined pole core 3 by performing a rotation operation following the shape of the flange portion 3 b of the pole core 3 by the cam mechanism of the winding device 131.
[0023]
c) Winding machine 14 for the main coil 5
As shown in FIG. 17, the winding machine 14 includes a tension generator 140, a winding device 141, a nozzle unit 142, a terminal processing mechanism 143, a pallet moving mechanism 144, a winding pack 145, and the like.
The tension generator 140 can generate a predetermined tension on the electric wire D.
The winding device 141 includes a path (not shown) for supplying the electric wire D to the nozzle portion 142, and a flange portion 3b of the pole core 3 and a cam mechanism (not shown) that is substantially similar to the flange portion 3b. It rotates at high speed while following the locus to be imitated.
As shown in FIG. 18, the nozzle portion 142 includes a plurality of (two in FIG. 18) winding nozzles 146 on the side surface of the nozzle portion 142, and the nozzle portion 142 rotates on the inner peripheral side of the pole core 3. On the other hand, the winding nozzle 146 supplies the electric wire D to the magnetic pole part of the pole core 3 so that the winding efficiency can be increased.
[0024]
The terminal processing mechanism 143 is a mechanism for holding a terminal (winding start line and winding end line) of the main coil 5 and performing a predetermined processing operation.
The pallet moving mechanism 144 has a function of rotating the pallet 12 to a predetermined position and a function of ascending / descending during winding processing and terminal processing.
The winding pack 145 is a wire supply pack, and houses the wire D for the main coil 5 therein.
This winding machine 14 determines the relative position of each pole core 3 and the winding nozzle 146 with respect to the axis of the yoke 2 by the cooperation of the winding device 141 and the pallet moving mechanism 144, and as shown in FIG. The nozzle portion 142 can be wound around a predetermined pole core 3 by performing a rotation operation following the shape of the flange portion 3 b of the pole core 3 by the cam mechanism of the winding device 141.
[0025]
d) Terminal processing device 15 of the shunt coil 4
This terminal processing device 15 temporarily fixes the terminal of the shunt coil 4 held by the terminal holding means 122 of the pallet 12 to the shunt terminal 7 assembled to the workpiece W. As shown in FIG. 12 includes a machine base 150 on which a terminal 12 is mounted, a terminal distribution arm 151, a terminal positioning mechanism 152, a terminal caulking mechanism 153, and the like.
The terminal distribution arm 151 holds the terminal of the shunt coil 4 held by the terminal holding means 122 of the pallet 12 and distributes it to a predetermined position of the shunt terminal 7 assembled to the workpiece W. The terminal distribution arm 151 is configured by a combination of a multi-axis robot and a plurality of loaders because complicated operation is required.
[0026]
The terminal positioning mechanism 152 is a mechanism for finally positioning the terminal of the shunt coil 4 to a predetermined position. That is, since the terminal distribution arm 151 grips and distributes the terminal of the shunt coil 4, the position of the terminal root portion of the shunt coil 4 temporarily fixed to the shunt terminal 7 becomes unstable. Accordingly, the terminal positioning mechanism 152 positions and inserts the terminal root portion of the shunt coil 4 into the root holding portion of the shunt terminal 7.
The terminal caulking mechanism 153 temporarily fixes (caulks) the terminal root portion of the shunt coil 4 to the shunt terminal 7.
[0027]
Next, the manufacturing process of the stator 1 is demonstrated based on FIG.20 and FIG.21.
FIG. 20 is a process block diagram for explaining the order of the processes, and FIG. 21 shows a production line in which the processes are arranged continuously and the conveyance between the processes is automated, and the production efficiency is dramatically improved. It is a conceptual diagram of the manufactured manufacturing process. The production line shown in FIG. 21 includes a conveying means V (for example, a belt) for conveying the pallet and a circulating means (not shown) for circulating the pallet (empty state) after the completion of processing.
Step 001: A pipe-shaped material is cut, or the cylindrical yoke 2 is formed by drawing or rounding with a press.
Step 002 ... The pole core 3 including the core portion 3a and the flange portion 3b is formed by cutting, cold forging, pressing, or the like.
Step 003... The pole core 3 is screwed, caulked, welded, etc. to the inner wall of the yoke 2 held by the work holding part 121 of the pallet 12 (see FIG. 22).
Step 004 ... An insulating structure is formed on the inner wall of the yoke 2 and the winding portion (core portion 3a) of the pole core 3. For example, powder coating may be used, or a resin bobbin may be attached to the pole core 3 in advance before the pole core 3 is fixed to the yoke 2 to form an insulating structure.
[0028]
Step 005 ... The winding start line 4a of the shunt coil 4 is drawn out by a predetermined length in advance by the winding machine 13, and then the shunt coil 4 is continuously wound around each of the pole cores 3 (3A to 3D). The line 4e is drawn out for a predetermined length. The winding process of the shunt coil 4 is shown in FIGS. Both terminals 4a and 4e of the shunt coil 4 can be pulled out by a predetermined length by a drawing mechanism (not shown) provided in the winding machine 13.
In this winding process, tension is applied to the electric wires D when winding the pole cores 3 so that the connecting wires of the shunt coils 4 can escape to the inner wall side of the yoke 2 when the main coil 5 is wound. When routing the wires, loosen the tension and make the crossovers slack. Alternatively, when winding around each pole core 3, apply tension, loosen the tension after the end of the predetermined winding, reverse the winding nozzle 136, and then rotate forward again (this causes the wire to become slack). After that, route the crossover.
After the winding of the shunt coil 4 is completed, the winding start wire 4a and winding end wire 4e of the drawn shunt coil 4 are held by the terminal holding means 122 of the pallet 12 (see FIG. 25).
[0029]
Step 006... The main coil 5 is wound on the upper layer of the shunt coil 4 by the winding machine 14. When the main coil 5 is wound, first, winding to two opposing pole cores 3 is simultaneously performed, and then a lead wire 5a having a predetermined length is formed, and the next two opposing pole cores 3 are formed. Winding to the same time. The winding process of the main coil 5 is shown in FIGS. The lead wires 5a and 5b of the main coil 5 can be drawn out by a predetermined length by a drawing mechanism (not shown) provided in the winding machine 14.
In this winding process, the connecting wire of the shunt coil 4 is connected to the inner wall of the yoke 2 so that the connecting wire of the already-wound shunt coil 4 does not interfere with the nozzle portion 142 (particularly the winding nozzle) of the winding machine 14. A means for escaping to the side is used. The means for escaping the connecting wire includes, for example, a guide arrow having a leading edge on the inner diameter side from the location of the connecting wire of the shunt coil 4, and when winding the main coil 5, the upper opening of the yoke 2 is provided. By inserting the guide arrow into the inside of the yoke 2, interference between the main coil 5 and the jumper wire of the shunt coil 4 can be prevented. In addition, after the guide arrow is inserted into the yoke 2 from the upper opening of the yoke 2, the guide arrow is expanded toward the inner wall side of the yoke 2 to prevent interference between the main coil 5 and the jumper wire of the shunt coil 4. You can also.
[0030]
Step 007: After the winding of the main coil 5 is completed (see FIG. 29), as shown in FIG. 30, the lead wires 5a and 5b of the main coil 5 are twisted for several turns to be unified.
Step 008... As shown in FIG. 31, the insulation 6 is attached (assembled) to the inner periphery of one opening end of the yoke 2. At this time, the lead wires 4a and 4e of the shunt coil 4 and the lead wires 5a and 5b of the main coil 5 are drawn from a coil lead portion 6b and a coil lead portion 6a formed in the insulation 6, respectively.
Step 009... Shunt terminals 7 (two pieces) are fixed to the insulation 6 attached to the yoke 2. As a means for fixing the shunt terminal 7 and the insulation 6, for example, as shown in FIG. 32, a circular protrusion 6 d is provided on the insulation 6, and circular fitting holes are formed in the base portions 70 and 71 of the shunt terminals 7 A and 7 B. 7a can be formed, and it can fix by inserting the protrusion 6d in the fitting hole 7a, and carrying out heat caulking. Alternatively, both may be fixed with an adhesive, or a metal shunt terminal 7 may be integrally formed with resin insulation 6 by insert molding or the like. Each shunt terminal 7 may be held (fixed) to the insulation 6 in advance before the insulation 6 is attached to the yoke 2.
[0031]
Step 010... The lead wires 5 a and 5 b of the main coil 5 are fixed by the insulation 6. Here, a U-shaped collar portion is provided in the insulation 6, a lead wire of the main coil 5 is inserted into the collar portion, the inlet portion of the collar portion is heat caulked, and closed by ultrasonic caulking or the like to close the main coil. Fix the 5 leader line. Thereby, the vibration resistance of the lead wire of the main coil 5 can be improved.
Step 011: A main terminal (called a hoop material) 8 is formed in a substantially U shape from a steel material or copper, a copper alloy or the like (see FIG. 33).
Step 012... As shown in FIG. 33, the main terminal 8 is attached to a portion where the lead wires 5a and 5b of the main coil 5 are to be connected to the connection bar 9, and is caulked and fixed temporarily.
[0032]
Step 013... The main terminal 8 is energized and heated to melt the insulating coating of the main coil 5, and the coating is peeled off to electrically connect the main terminal 8 and the main coil 5. Here, since a surplus line is generated above the main terminal 8, the lead wires 5a and 5b of the main coil 5 are cut with a predetermined dimension as required (see FIG. 34). At this time, if the width dimension of the main terminal 8 is set to a predetermined dimension in advance so that the main terminal 8 is not cut at the time of cutting the remaining line, the life of the cutting cutter can be extended.
Step 014... The resistance value between the two main terminals 8 on the + side or the − side is measured, and the insulation state between the main coil 5 and the yoke 2 is determined from the measured value.
[0033]
Step 015: Both terminals of the shunt coil 4 held by the terminal holding means 122 of the pallet 12 are removed from the terminal holding means 122 and temporarily held by a holding mechanism provided in the insulation 6 (see FIG. 35). For example, as shown in FIGS. 36 and 37, the insulation 6 includes a groove 6e for inserting the lead wire root portion of the shunt coil 4 and a lead wire root portion of the shunt coil 4 inserted into the groove 6e. A holding mechanism including a holding piece 6f for temporary holding is provided.
The operation when the lead wire root portion of the shunt coil 4 is held by this holding mechanism will be described with reference to FIG. In a state where the holding piece 6f is pressed by the holding piece pressing means 16 and the opening width of the groove 6e is widened, the lead wire root portion of the shunt coil 4 is inserted into the groove 6e by the coil end pressing means 17. Next, by retracting the holding piece pressing means 16 to release the pressing force to the holding piece 6f, the holding piece 6f returns to its original position by elastic force and the shunt coil 4 inserted into the groove 6e is pulled out. Hold the line root. FIG. 38 shows the process of holding the lead wire root portion of the shunt coil 4 connected to the + side shunt terminal 7A, but the lead wire root portion of the shunt coil 4 connected to the negative side shunt terminal 7B is shown. The same holds for holding.
[0034]
Step 016: The joint portions 7c and 7f provided on the shunt terminal 7 are caulked, and the lead wire root portion of the shunt coil 4 temporarily held by the holding mechanism of the insulation 6 is fixed. The joint joint portions 7c and 7f of the shunt terminal 7 are provided in a V shape that is larger than the wire diameter of the shunt coil 4, and a folded portion 7c1 for preventing the shunt coil 4 from being crushed at one end portion of the V shape. 7f1 is provided. Here, the lead wire root portion of the shunt coil 4 can be caulked and fixed by pressurizing the one where the folded portions 7c1 and 7f1 of the joint joint portions 7c and 7f are provided to close the V-shaped opening. .
Step 017... As shown in FIG. 39, the joint of the positive shunt terminal 7A is energized and heated through a pair of electrodes 18 and 19 to melt the coating film of the shunt coil 4, and the wires of the shunt coil 4 and the shunt terminal 7 is electrically connected. The extra line of the shunt coil 4 generated in this process is cut into a predetermined dimension. Although FIG. 39 shows the + side shunt terminal 7A side, the same operation is performed on the − side shunt terminal 7B side.
[0035]
Step 018: The resistance value between the two shunt terminals 7A and 7B is measured, and the insulation state between the shunt coil 4 and the yoke 2 is determined from the measured value.
Step 019... The ground connection portion (connecting means with the yoke 2) of the − side shunt terminal 7 B is connected to the spigot end portion of the yoke 2 by resistance welding, brazing, or the like.
Step 020... The resistance value between the two main terminals 8 on the + side or the − side is measured, and the insulation state between the main coil 5 and the yoke 2 is determined from the measured value.
Step 021... The connection bar 9 is formed into a predetermined shape (in this embodiment, semicircular) from a conductive material such as iron, copper, or aluminum.
Step 022... As shown in FIG. 40, the connection bar 9 is attached to the yoke 2. Here, the lead wire 10 connected to the connection bar 9 may be connected in advance by welding or the like before attaching the connection bar 9 to the yoke 2, or connected after attaching the connection bar 9 to the yoke 2. Also good.
Step 023 ... The + side shunt terminal 7A and the two + side main terminals 8A are mechanically and electrically connected to the connection bar 9 by welding or brazing.
[0036]
Step 024 ... The brush 11 in which the connecting wire 11a is insert-molded from powdered carbon / copper powder or the like is formed by sintering.
Step 025... The brush 11 is mechanically and electrically connected to the negative side main terminal 8B by welding or brazing.
Step 026: A resistance measuring probe is brought into contact with both ends of the brush 11 or the main terminal 8 to measure the resistance value between the brushes 11 or between the main terminals 8, and the resistance value of the main coil 5 becomes a predetermined value. Check that there is.
In this case, voltage drop measurement may be used instead of measuring the resistance value. Or the temperature of the workpiece | work W may be measured and the calculation apparatus for temperature correction may be provided.
[0037]
Step 027 ... A resistance measuring probe is brought into contact with the base portion 120 of the + side shunt terminal 7A and the base portion 120 of the-side shunt terminal 7B, and the resistance value between both the + side and-side shunt terminals 7 is measured. The resistance value of the shunt coil 4 is inspected to be a predetermined value.
Step 028 ... In order to detect an interlayer rare short-circuit between the main coil 5 and the shunt coil 4, an impulse test probe is brought into contact with the base portion 120 of the + side shunt terminal 7 A and the base portion 120 of the − side shunt terminal 7 B. Then, an impulse voltage is applied between both the + side and the − side shunt terminals 7 to make a comparison with a non-defective product. As a result, even fine defects that cannot be detected by resistance measurement can be detected, and a high-quality stator 1 can be provided. In addition, this process is implemented as needed especially in the case of the stator 1 for which a durable life is required or a large current flows.
[0038]
(Effect of this embodiment)
In the stator 1 of this embodiment, the shunt coil 4 thinner than the main coil 5 is wound around the pole core 3 and then the main coil 5 is wound on the upper layer of the shunt coil 4. Is firmly held between the main coil 5 and the inner wall of the yoke 2. Thereby, the disconnection of the shunt coil 4 in which one ultrafine wire is wound in multiple layers can be prevented, and the stator 1 having excellent vibration resistance can be provided. In addition, by directly winding the shunt coil 4 and the main coil 5 on the pole core 3 that is fixed to the yoke 2 in advance, the work efficiency is high and automation is easy. Therefore, the inexpensive stator 1 can be provided. it can.
[0039]
After the shunt coil 4 and the main coil 5 are wound around the pole core 3, the main terminal 8 and the shunt terminal 7 are joined to the main coil 5 formed by collecting many thin wires and the shunt coil 4 having only one thin wire. Since they can be connected sequentially and reliably, a highly reliable stator 1 can be provided.
The + side shunt terminal 7A includes a joint joint portion 7b to the connection bar 9 and a joint joint portion 7c to the shunt coil 4. The − side shunt terminal 7B includes a joint joint portion 7e to the yoke 2; Since the joint joint portion 7f with the shunt coil 4 is provided, it is possible to provide the stator 1 with high reliability of individual connection portions and high vibration resistance.
Further, since the-side shunt terminal 7B is electrically connected to one opening end face of the yoke 2, it is possible to easily join the ground side without modifying the insulation structure of the yoke 2.
[0040]
  In the present embodiment, after the main terminal 8 is electrically connected to the main coil 5, the insulation state between the main coil 5 and the yoke 2 is inspected, and then the shunt coil 4 is electrically connected to the shunt terminal 7. After the connection, the insulation state between the shunt coil 4 and the yoke 2 is inspected. Subsequently, the-side shunt terminal 7B is electrically connected to the yoke 2, and then again between the main coil 5 and the yoke 2. Next, after electrically connecting the + side shunt terminal 7A and the + side main terminal 8A (two pieces) to the connection bar 9, the main coil 5 and the shunt coil 4 are short-circuited. The inspection and the resistance value of the main coil 5 and the resistance value of the shunt coil 4 are inspected. By inspecting the electric circuit according to this procedure, it is possible to reliably detect defects related to the ground, short circuit, and resistance value of the main coil 5 and the shunt coil 4, so that the high quality and high reliability are achieved.Stator 1Can provide.
[0041]
After winding the shunt coil 4 around the pole core 3, the connecting wire of the shunt coil 4 is released to the inner wall side of the yoke 2, so that the winding nozzle 14 and the shunt coil 4 of the winding machine 14 are wound when the main coil 5 is wound. Interference with the connecting wire can be prevented.
It is generated when the main coil 5 is wound around the pole core 3 by pulling out the winding start line and the winding end line of the shunt coil 4 by a predetermined length and holding both ends on the terminal holding means 122 of the pallet 12. It is possible to prevent the shunt coil 4 from being caught.
In the winding process of the main coil 5, the winding work can be speeded up by simultaneously winding the two opposing pole cores 3 and then simultaneously winding the next two opposing pole cores 3. Can be improved.
[0042]
(Second embodiment)
In this embodiment, an electrical connection method between the shunt terminal 7 and the shunt coil 4 will be described. 41 is a plan view showing a connection method between the shunt terminal 7 and the shunt coil 4, and FIG. 42 is a side view.
As shown in FIG. 41, the shunt terminal 7 is provided with a flat joint joint portion 7c wider than the wire diameter of the shunt coil 4.
The shunt coil 4 is disposed in the vicinity of the joint joint portion 7c of the shunt terminal 7 without peeling off a predetermined terminal, and is electrically connected to the joint joint portion 7c by the following welding machine.
As shown in FIGS. 41 and 42, the welding machine includes an electrode 20 that receives the joint portion 7c, an electrode 21 that pressurizes the joint portion 7c, and an electrode 22 that generates heat before pressurization. Yes.
With this welding machine, the film of the shunt coil 4 is heated and melted, the film is peeled off, and the joint joint portion 7c of the shunt terminal 7 and the electric wire of the shunt coil 4 are pressurized and energized, thereby the shunt terminal 7 and the shunt coil. 4 is connected electrically.
[0043]
(Third embodiment)
In this embodiment, a method of holding the lead wire root of the shunt coil 4 will be described.
43 is a plan view showing a method of holding the lead wire root of the shunt coil 4, and FIG. 44 is a side view.
In this embodiment, as shown in FIGS. 43 and 44, after the lead wire 4a of the shunt coil 4 is held by the joint portion 7c of the + side shunt terminal 7A, an opening formed in the insulation 6 is formed. The lead wire root of the shunt coil 4 is held by encapsulating with resin 23 (UV resin, adhesive, etc. is optimal). In addition, the number 24 in a figure is a nozzle for enclosing resin. 43 and 44 show the + side shunt terminal 7A, the same can be applied to the − side shunt terminal 7B.
[Brief description of the drawings]
FIG. 1 is a plan view showing a structure of a stator.
FIG. 2 is a longitudinal sectional view showing a structure of a stator.
FIG. 3 is a conceptual diagram of an electric circuit according to the present embodiment.
FIG. 4 is a plan view showing a yoke and a pole core.
FIG. 5 is a longitudinal sectional view showing a yoke and a pole core.
6A is a plan view of insulation and FIG. 6B is a cross-sectional view.
FIG. 7 is a partial plan view of an insulation showing a coil lead-out portion.
FIG. 8 is a partial plan view of an insulation showing a coil lead-out portion.
9A is a partial plan view of an insulation showing a coil lead-out portion, and FIG. 9B is a side view thereof.
FIG. 10 is a three-sided view of a + side shunt terminal.
FIG. 11 is a three-side view of a + side shunt terminal (another example 1).
FIG. 12 is a three-side view of a + side shunt terminal (another example 2).
FIG. 13 is a three-sided view of a − side shunt terminal.
14A is a plan view of a pallet and FIG. 14B is a cross-sectional view.
FIG. 15 is a schematic view showing a configuration of a shunt coil winding machine.
FIG. 16 is a perspective view showing a winding process of a shunt coil.
FIG. 17 is a schematic view showing a configuration of a main coil winding machine.
FIG. 18 is a perspective view showing a winding process of the main coil.
FIG. 19 is a schematic diagram showing a configuration of a terminal processing apparatus for a shunt coil.
FIG. 20 is a process block diagram illustrating the process order of the embodiment.
FIG. 21 is a conceptual diagram of a manufacturing process of the present example.
FIG. 22 is a perspective view showing a step of the production line.
FIG. 23 is a plan view showing a state at the start of winding of the shunt coil.
FIG. 24 is a plan view showing a state at the end of winding of the shunt coil.
FIG. 25 is a perspective view illustrating a winding process of a shunt coil.
FIG. 26 is a plan view showing a state at the start of winding of the main coil.
FIG. 27 is a plan view showing a state in the middle of winding of the main coil.
FIG. 28 is a plan view showing a state at the end of winding of the main coil.
FIG. 29 is a perspective view showing a winding process of the main coil.
FIG. 30 is a perspective view showing a terminal treatment process of the main coil.
FIG. 31 is a perspective view showing an assembly process of insulation.
FIG. 32 is a plan view showing a state in which the shunt terminal is fixed to the insulation.
FIG. 33 is a perspective view showing an assembly process of insulation.
FIG. 34 is a perspective view showing a state where the main terminal is assembled.
FIG. 35 is a perspective view showing a terminal arranging step of the shunt coil.
FIG. 36 is a plan view showing a terminal holding mechanism (+ side) of the shunt coil.
FIG. 37 is a plan view showing a terminal holding mechanism (− side) of the shunt coil.
FIG. 38 is an operation explanatory view of the terminal holding mechanism (+ side) of the shunt coil.
FIG. 39 is a plan view showing a joining process between the shunt coil and the + side shunt terminal.
40 is a perspective view showing a connection bar assembling step. FIG.
FIG. 41 is a plan view showing a joining process of the shunt coil and the + side shunt terminal (second embodiment).
FIG. 42 is a side view showing a joining process of the shunt coil and the + side shunt terminal (second embodiment).
FIG. 43 is a plan view showing a method for fixing the terminal root portion of the shunt coil (third embodiment).
FIG. 44 is a side view showing a method for fixing a terminal root portion of a shunt coil (third embodiment).
[Explanation of symbols]
1 Stator
2 York
3 Pole core
4 Shunt coil
5 Main coil
6 Bushing insulation (terminal holding means)
6a Main coil lead-out part
6b Shunt coil drawer
7 Shunt terminal
7b Joint joint with the connection bar of the + side shunt terminal
7c Joint joint with the shunt coil of the + side shunt terminal
7e-Joint part of the shunt terminal with the yoke
7f-Joint joint with shunt coil of-side shunt terminal
8 Main terminal
9 Connection bar (terminal connection means)
D electric wire

Claims (1)

A cylindrical yoke,
A plurality of pole cores provided inside the yoke;
A main coil wound directly around this pole core,
Using a wire thinner than this main coil, and a shunt coil wound directly around the pole core ,
A main terminal which is a means for connecting the main coil;
A shunt terminal which is a means for connecting the shunt coil;
A terminal holding means mounted on one open end of the yoke to hold the shunt terminal;
Terminal connecting means for electrically connecting the shunt terminal on the + side and the main terminal on the + side;
In a state where the pole core is fixed to the yoke in advance, the shunt coil connected to one is wound around at least two pole cores, and then the main coil is wound around the plurality of pole cores. A rotating electric machine stator,
First, after electrically connecting the main terminal to the main coil, the insulation state between the main coil and the yoke is inspected,
Subsequently, after electrically connecting the shunt coil to the shunt terminal held by the terminal holding means, inspecting the insulation state between the shunt coil and the yoke,
Subsequently, after electrically connecting the-side shunt terminal to the yoke, again inspecting the insulation state between the main coil and the yoke,
Subsequently, after electrically connecting the + side shunt terminal and the + side main terminal to the terminal connecting means, a short circuit inspection between the main coil and the shunt coil, and a resistance value of the main coil, A method of manufacturing a stator of a rotating electric machine, wherein a defect in an electric circuit is detected by inspecting a resistance value of the shunt coil .

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