JPH0135589B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a stator for a motor and a method for manufacturing the same.

Applicant's European patent application no. It consists of a plurality of coils each wound around a coil support member, and a plurality of lead wires respectively connected to the plurality of coils, and is on a coil support member in a predetermined relationship among the plurality of coil support members. the coils are connected in series to each other by intermediate portions of coil wire forming the coils;
A plurality of terminal housings each accommodating a terminal are mounted on the core, each terminal housing comprising a cavity accommodating a terminal, an inner wall and an outer wall facing radially inwardly and outwardly of the core, respectively. A pair of coil wire insertion slots communicating with the cavity are provided on both sides of the terminal housing, and an end of the coil wire is inserted from each coil into the cavity through the slot in the inner wall of one of the terminal housings. extending through the terminal housing and terminating in the slot in the outer wall of the terminal housing and having a terminal received within the cavity to which the end of the coiled wire is connected and A stator for a motor is described in which each of the lead wires is connected to each of the coils through a wire.

The above-mentioned known stator is for a split-phase bipolar induction motor, and in this stator, the plurality of terminal housings are mounted side by side at one location on the core.

An object of the present invention is to provide a stator for a step motor that can be manufactured using a winding machine with almost no manual steps, and a method for manufacturing the stator that can be easily automated. be.

Step motors are generally classified by the number of phases and the number of coils on the stator. The number of phases in a step motor is equal to the number of consecutive coil wires on the stator. For example, in the case of a step motor stator with 4 phases and 8 coils, it has 4 continuous coil wires, and 1 coil on 2 coil support members.
It is wound with a single coil of wire, and each phase consists of two coils. Further, in the case of a stator of a step motor having four phases and 16 coils, there are four continuous coil wires, and each coil wire winds the coils on four coil support members. In the case of a 3-phase 12-coil step motor stator, it has three continuous coil wires, and each coil wire winds four coils.
In the case of a two-phase, eight-coil step motor stator, each of the four coils is wound by two continuous coil wires.

The stator coil of the step motor is wound onto a coil support member by a winding machine. A winding machine draws coil wire from a coil wire supply and winds it around the coil support member such that the coils in each phase are connected to each other by an intermediate portion of the coil wire. After the stator is removed from the winding machine, the wires extending around the core must be cut and discarded, leaving the ends of the wires extending from the coils.
Then connect the end of the wire to the lead wire.

The process of cutting predetermined portions of the coiled wire is typically performed manually, and therefore errors occur. Therefore, after connecting the lead wires to the coils, the stator must be carefully inspected and, if necessary, reworked.

The stator of the present invention includes a core, a plurality of coil support members integrally formed with the core at equal angular intervals, and extending inwardly toward the center of the core; It comprises a plurality of coils each wound around the periphery, the plurality of coils are divided into a plurality of sets consisting of a plurality of coils in a predetermined positional relationship, the coils in each set are connected in series with each other, and the coils in each set are In a stator for a step motor, in which lead wires are connected to the first and last coils in each set, all of the plurality of coils in each set are wound with one continuous coil wire, and the middle of the coil wire is wound with a single continuous coil wire. a section extends between each coil in each set, the intermediate section connects each coil in each set in series, and the first and last coils of the coils in each set are connected in series. A plurality of terminal housings are disposed on the core adjacent to the housing, each terminal housing having a cavity containing a terminal, an outer wall facing radially outwardly of the core, and an outer wall facing radially inwardly of the core. an inner wall, the outer and inner walls each having a coil wire insertion slot, and an end of the coil wire adjacent to the first coil is adjacent to the first coil of the terminal housing. extending from the inner wall side through the coil wire insertion slot in the inner wall, across the cavity to the coil wire insertion slot in the outer wall, and terminating at the coil wire insertion slot in the terminal housing; electrically connected to a terminal housed within the
The end of the coil wire on the last coil side passes from the inner wall side of the terminal housing adjacent to the last coil, passes through the coil wire insertion slot in the inner wall, and crosses the cavity to the outer wall. and ends at the coil wire insertion slot, and is electrically connected to a terminal housed in the cavity of the terminal housing, and the lead is connected to each terminal. It is characterized by the fact that the lines are connected. Further, in the manufacturing method of the present invention, each of the terminal housings is mounted on the core, and a coil wire is drawn out from a coil wire supply source so that the coil wire is adjacent to the first coil of one of the plurality of coil sets. After passing the coil wire from the outer wall side of the terminal housing through the coil wire insertion slot in the outer wall, the cavity, and the coil wire insertion slot in the inner wall, winding the first coil, and further The coil wire is stretched to wind each coil in the set, and after winding the last coil in the set, from the side of the inner wall of the terminal housing adjacent to the last coil to the coil on the inner wall of the terminal housing. The coil wire is passed through the wire insertion slot, the cavity, and the coil wire insertion slot in the outer wall, and then the coil wire is passed through the coil wire insertion slot, the cavity, and the outer wall of the first terminal housing of the next coil set. After passing through the coil wire insertion slot in the inner wall, all the coils of the set are wound and the coil wire insertion slot, the cavity and All coils of all sets are wound with one continuous coil wire so as to pass through the coil wire insertion slot in the outer wall, and the coil wire extends between the terminal housings without passing through the coil. selectively cutting a portion, inserting a terminal into the cavity of each of the terminal housings, electrically connecting a portion of the coiled wire across the cavity to the terminal, and connecting a lead wire to the terminal. It is characterized by being connected.

The current state of the art in this field is U.S. Pat. No. 4,130,331;
It is described in No. 4118103, etc.

Embodiments of the present invention will be described in detail below with reference to the drawings.

In Figs. 1 and 2, a four-phase 8 according to an embodiment of the present invention is shown.
The stator 6 for a coil step motor is equipped with a cylindrical core 8 having a circular cross section and made by laminating a plurality of identical thin plates made of a magnetic material. The core 8
has eight radially inwardly extending arms formed in a pair with its core 8 and equiangularly spaced apart. The eight arms constitute coil support members 1, 2, 3, 4, 1', 2', 3', and 4', respectively. Note that the coil support members indicated by numbers with a dash are diametrically opposed to the coil support members indicated by the same numbers without a dash. A molded terminal housing support member (hereinafter simply referred to as a housing support member) 14 is attached to the upper surface 12 of the core 8 and fixed to the core 8 . The housing support member 14 includes a housing support ring 16 having the same diameter as the core 8. This housing support ring 1
6 is provided with a plurality of hollow arms 18 pointing radially inward. Each arm 18 is provided with downwardly extending side walls 26 on both sides, and the coil supporting members 1-4, 1'-
4' is inserted. Additionally, at the free end of the arm 18, there is a flange 22 that rises upward.
is provided. This flange 22 is for holding down the coil 88 which is wound from above the arm 18 around the coil supporting members 1-4, 1'-4'. The housing support member 14 further extends downwardly and includes a flange 24 extending into the core 8 between the coil support members 1-4, 1'-4'. This flange 24 has a smooth surface, and the coil 88 is pressed against this flange 24.
is wound. The housing support member 14 may be formed from any insulating material, but is preferably formed from a thermoplastic material such as nylon.

Multiple terminal housings 10, 20, 30, 4
0, 10', 20', and 30' project upwardly from the housing support ring 16. The terminal housing 10, 20, 30, 40, 10', 20', 3
0' are arranged at intervals in the circumferential direction such that one terminal housing is located between each coil support member except between the coil support members 4 and 1'. A strain relief member 28 for the lead wire is provided between the coil support members 4 and 1'. Terminal housing 10' faces terminal housing 10 approximately, but not exactly, diametrically.

As explained below, the terminal housing 10 cooperates with the coil support member 1 and the terminal housing 1
0' cooperates with the coil support member 1'. The number of terminal housings is one less than the number of coil supports 1-4, 1'-4' and the number of coils 88 on core 8.

Terminal housing 10, 20, 30, 40, 1
0', 20', and 30' all have the same structure, so the structure will be explained next using the terminal housing 10 as an example.

As shown in FIGS. 3 to 6, the terminal housing 10 includes a terminal receiving surface 32 on its upper surface, an outer wall 34 on the outer side in the radial direction, an inner wall 36 on the radial side, and a pair of end walls 38 located in the circumferential direction. ing. The outer wall 34 has a recess 39 at its lower end (as viewed in Figures 5-6).
have. This recess 39 receives and guides the wire of the coil 88 when it is wound around the core 8.

The terminal receiving cavity 42 is connected to the terminal receiving surface 32.
The terminal housing 10 extends from the terminal housing 10 into the terminal housing 10 . The cavity 42 has a size and shape (generally rectangular) such that a generally rectangular terminal 54 as shown in FIG. 7 can be inserted therein. Further, the outer wall 34 and the inner wall 36 are provided with slots 44 and 46, respectively, in alignment with each other, for passing the coil wires therethrough. Note that the slot 44 in the outer wall 34 is shallower than the slot 46 in the inner wall 36. A column 48 stands up from the bottom wall 50 of the cavity 42. The upper end of this post 48 is located at the same height as the bottom of the slot 46. As will be described later, lead wire insertion slots 52 for passing insulated lead wires are provided in both side walls 34 and 36, respectively. The lead wire insertion slots 52 in both side walls 34 and 36 have the same depth.

As shown in FIG. 7, each terminal 54 consists of a pair of mutually parallel plate parts 56 and 58 whose lower ends are joined by a curved part 60. A flange 62 is provided at the upper end of one plate portion 56 and extends toward the other plate portion 58 to form a seam therebetween.

Both plate portions 56 and 58 are provided with downwardly extending coil wire insertion slots 64 aligned with each other. The coil wire insertion slot 64 communicates with a wide opening 66 provided in the curved portion 60. A narrow shoulder 68 is provided at the lower end of the coil wire insertion slot 64. This shoulder portion 68 is formed by making L-shaped cuts in the metal material that forms the terminal 54 at the portions corresponding to both sides of the slot 64, and then turning up the portions and returning them to approximately the original position. form. Through this operation, slot 6
The portions on both sides of 4 protrude slightly closer to each other to form a shoulder 68 having a width of about 0.1016 mm. This shoulder 68 breaks through the thin but hard varnish coating of the coiled wire.

Additionally, both plate portions 56,58 are provided with aligned lead wire insertion slots 70 extending downwardly from wide openings 72 provided in the upper ends of the flange 62 and both plate portions 56,58. The slot 70 has a width such that when an insulated lead wire is inserted into the slot 70, the insulation coating of the lead wire is ruptured by the side wall of the slot 70 and the wire core inside comes into electrical contact with the terminal 54. have. Such terminals 54 are manufactured by stamping in the form of a continuous body in which a plurality of terminals 54 are connected via slabs 76 to a long support strip 74, so that each Terminal 54 is disconnected from support strip 74. Further, each terminal 54 is connected to the plate portion 5.
6 and 58, and when the terminal 54 is inserted into the cavity 42, the barbed portions 78 are inserted into the cavity 42.
into the inner wall of the cavity 4 and connect the terminal 54 to the cavity 4.
It is designed to be kept within 2.

Next, with particular reference to FIGS. 8-12, the coil 88
The winding method and the connection method between the lead wire and the coil 88 will be explained. The coil winding process is carried out by Windermatic Systems, Inc. or Esthetics Machinery and Terminal Division of Esthetics International (both Fort, Indiana).
This can be done using a known winding machine such as Wayne Wayne.

Figure 8 shows terminal housings 10, 20, 30, 4.
0, 10', 20', 30' and coil support members 1~
4, 1' to 4' schematically show the angular positional relationship. As shown in FIG. 9, the coil wire 84 pulled out from the spool (not shown) first receives a terminal housing (hereinafter simply referred to as the housing).
10 of the slots 44, 46. The winding machine now operates on the coil support member 1 to wind the coil 88 around it. A portion 86 of the coil wire 84 therefore extends from the housing 10 to the coil 88 wound on the coil support member 1 . Next, the coil wire 84 is connected to the housing support member 1
4 through the recess 39 of the outer wall 34 of the housing 20, 30, 40 and the coil support member 1'
(located on the diametrically opposite side of the previously wound coil support member 1). Here, the coil 88 is wound on its coil support member 1' by a winding machine.
wrapped around. Next, the coil wire 84 is transferred from the coil 88 of the coil support member 1' to the housing 1.
0' and the inner wall 36 of its housing 10'
from the slot 46 in the outer wall 34 to the slot 44 in the outer wall 34. Therefore, the intermediate portion 90 of the coil wire 84
extends from the coil support member 1 to the coil support member 1', and one end 92 of the coil wire 84 extends from the coil support member 1' to the housing 10'.

The coiled wire 84 is then turned clockwise around the housing support member 14 toward the housing 20 and into the slot 44 in the outer wall 34 of the housing 20.
passed inside. This causes intermediate section 94 to extend from outer wall 34 of housing 10' to outer wall 34 of housing 20, as shown in FIG. Further, the coil wire 84 is extended through the slot 46 in the inner wall 36 of the housing 20, wrapped around the coil support member 2, and then passed around the housing support member 14 again. It extends to the coil support member 2' on the diametrically opposite side. After winding the coil 88 around the coil support member 2', the coil wire 84 is passed through the slots 46, 44 from the inner wall 36 side of the housing 20'. In this way, the coil 88 is wound around the pair of coil support members facing each other in the diametrical direction, and finally, as shown in FIG. 10, when the coil 88 is wound around the coil support member 4',
The coil wire from the coil 88 on the coil support member 4' is inserted into the slot 4 from inside the housing 30'.
6,44. Therefore, the slots 44, 46 of the housing 30' pass both the portion 92 coming from the coil 88 on the coil support member 3' and the portion 92 coming from the coil 88 on the coil support member 4'. become.

The winding process described above is carried out continuously, and when the process is completed, the coil wire 84 is continuous in all the passes shown in FIG. 10 and is not broken anywhere. After removing the stator 6 from the winding machine, the terminals 54 are inserted into the cavities 42 of each housing using an insertion punch 93 (FIG. 13), and at the same time the cutting blade 93 is inserted into the outer wall 3 of each housing.
4 and cut all lines extending outward from the outer wall 34. This causes the intermediate section 94 exiting from the outer wall 34 to be cut off.

When this terminal insertion and line cutting process is completed, the first
As shown in Figure 1, a pair of diametrically opposed coils 88 are connected in series by an intermediate section 90, with ends 86, 92 of each coil 88 extending into an adjacent housing. The terminal insertion and line cutting process is described in US Pat. No. 4,099,316 and US Pat.
It is desirable to use a device such as that described in No. 3984908, modified for use with stator coils.

In the final stage of assembling the stator of this embodiment, as shown in FIG. 12 (the coil support member is omitted in FIG. 12), the lead wires 96 are moved in a direction perpendicular to their axis to lead each housing. Insert into the wire insertion slot 52 and the lead wire insertion slot 70 of the terminal 54. In this embodiment, the leads 96 extend inside the stator and over the coils 88 and connect to the inner wall 80 of the strain relief means 28 and two spaced apart wires.
It is passed between two outer walls. The inner wall 80 and outer walls 82 define a restricted passageway for guiding and holding the lead wire 96 from the housing support member 14.

As shown in FIG. 1, the completed stator 6 of this embodiment has an organized and clean appearance, and the electrical connections between the lead wires 96 and the coils 88 are well protected. Therefore, the stator of this embodiment can withstand not only normal handling but also rough handling in the next step in manufacturing the motor.

In the manufacturing method described in detail above, almost all operations can be performed using a winding machine. This has the great advantage of eliminating manual steps such as connecting wires. Therefore, by using the method of the invention, the manufacturing cost of the stator can be significantly reduced.

FIG. 14 schematically shows the stator 6 for a four-phase eight-coil step motor of the above embodiment. This FIG. 14 is for helping understanding of FIGS. 15 and 16, and the same numbers as in FIGS. 1 to 12 indicate the coil support member and the housing. Note that the lead wires are omitted.

A stator for a three-phase, 12-coil (four coils per phase) step motor according to another embodiment of the invention shown in FIG. The coil support member 98 is then wound around the coil support member 98.
8 to coil support members 98'-98''-98, and each of the coil support members 98', 98'', 9
8 and then passed through the housing 104'. Similarly, the next coil wire is the housing 106.
-Coil support member 100-100'-100''-1
00-housing 106', each coil support member 100, 100', 100'',
It is wrapped around 100. Similarly, the third coil wire is connected to the housing 108-coil support member 1.
02-102'-102''-102-housing 108' and is wound around each of the coil support members 102, 102', 102'', 102.

A two-phase, eight-coil (four coils per phase) step motor stator according to another embodiment of the present invention shown in FIG. 16 has two coil wires, and the first coil wire is connected to the housing 114. Coil support member 1
10-110'-110''-110-housing 114' are extended and wrapped around each coil support member 110, 110', 110'', 110. Similarly, the second coil wire is connected to the housing 116-coil support member 112-112'-1.
12''-112-housing 116' and each coil support member 112, 112', 1
12″, 112.The first to
As in the case of the embodiment shown in FIG. 12, it is desirable that the coil wires between the respective coil supporting members be passed around the stator.

When winding the coils on the stator of the embodiment shown in Figs. 15 and 16, the winding machine is programmed to operate in the pattern shown in Figs. 15 and 16, and one coil wire is used to wind all the coils. Then, as in the previous embodiment, unnecessary portions of the coil wire, that is, portions extending between the housings without passing through the coil support member, are cut. Stators with other winding patterns can be wound using similar principles.

In the case of a stator for a step motor, there are always coils which may be connected in common, and if necessary such coils may share one housing and terminals. Alternatively, the lead wires connected to such a coil may be connected to each other by crimping or the like.

[Brief explanation of drawings]

FIG. 1 is a perspective view of a stator for a four-phase, eight-coil step motor according to an embodiment of the present invention, FIG. 2 is a perspective view of a core and housing support member used in the stator, and FIG. 3 is a perspective view of the housing. A plan view of a part of the support member, FIG. 4 is shown in FIG.
Figure 5 is a cross-sectional view taken along the - line in Figure 4, Figure 6 is a cross-sectional view taken along the - line in Figure 4, and Figure 7 shows a terminal used in the stator in Figure 1 connected to the support strip. FIG. 8 is a diagram showing the relative positional relationship between the terminal housing and the coil support member in the embodiment shown in FIG. Diagram to explain,
Figure 13 is a view of the same part as Figure 6, showing the terminal being inserted into the terminal housing and the coil wire being cut, and Figure 14 is a schematic diagram showing the route of the stator coil wire in Figure 1. Figure 15
16 are diagrams each schematically showing a route along which a stator coil wire of another embodiment of the present invention extends. 1, 2, 3, 4, 1', 2', 3', 4'... Coil support member, 8... Core, 34... Outer wall, 1
0, 20, 30, 40, 10', 20', 30'...
...Terminal housing, 42...Cavity, 36...
...Inner wall, 44, 46...Coil wire insertion slot, 54...Terminal, 88...Coil, 96...Lead wire.

Claims (1)

[Scope of Claims] 1. A core, a plurality of coil support members integrally formed with the core at equal angular intervals and extending inward toward the center of the core, and a plurality of coil support members of the plurality of coil support members. It comprises a plurality of coils each wound around the periphery, the plurality of coils are divided into a plurality of sets consisting of a plurality of coils in a predetermined positional relationship, the coils in each set are connected in series with each other, and the coils in each set are In a stator for a step motor, in which lead wires are connected to the first and last coils in each set, all of the plurality of coils in each set are wound with one continuous coil wire, and the middle of the coil wire is wound with a single continuous coil wire. a section extends between each coil in each set, the intermediate section connects each coil in each set in series, and the first and last coils of the coils in each set are connected in series. A plurality of terminal housings are disposed on the core adjacent to the housing, each terminal housing having a cavity containing a terminal, a radially outwardly facing outer wall of the core, and a radially inwardly facing outer wall of the core. an inner wall, the outer wall and the inner wall each having a coil wire insertion slot, and an end of the coil wire on the first coil side of the terminal housing adjacent to the first coil. extending from the inner wall side through the coil wire insertion slot in the inner wall, across the cavity to the coil wire insertion slot in the outer wall, and terminating at the coil wire insertion slot in the terminal housing; electrically connected to a terminal housed in a cavity, the end of the coil wire on the last coil side extending from the inner wall side of the terminal housing adjacent to the last coil to the inner wall side of the terminal housing; a coil wire insertion slot extending across said cavity through a coil wire insertion slot to said coil wire insertion slot in said outer wall, and terminating in said coil wire insertion slot, and electrically connected to a terminal housed within said cavity of said terminal housing. , and the lead wires are connected to each of the terminals. 2. Each of the terminals has a coil wire insertion slot and a lead wire insertion slot, the end of the coil wire is inserted into the coil wire insertion slot, and one end of the lead wire is inserted into the lead wire insertion slot. The stator according to claim 1, wherein the stator is inserted into a stator. 3. The terminal housing is integrally formed with and extends from a support ring attached to one side of the core, and the intermediate portion of the coil wire is wound around the outside of the core. A stator according to claim 1 or 2. 4 The number of the coils is n, the number of the terminal housings is n-1, the number of coils in each set is 2, and the terminal housing is located between each of the plurality of coils. Claim 1 characterized in that one piece is arranged in each place except for one place.
3. The stator according to any one of items 3 to 3. 5. A patent claim characterized in that means is provided at the one location between each of the plurality of coils, where the terminal housing is not provided, for guiding the lead wire and serving as a strain relief for the lead wire. The stator according to item 4. 6. The terminal housing and the means for guiding the lead wire and serving as strain relief thereof are both integrally formed with a support ring attached to one side of the core. The stator according to range item 5. 7. Claim 1, wherein the number of said coils and coil support members is eight each, and each set of coils is comprised of a pair of coils facing each other in the diametrical direction of said core. The stator according to any one of Items 6 to 6. 8. A core, a plurality of coil support members formed integrally with the core at equal angular intervals and extending inward toward the center of the core, and each coil support member wound around the plurality of coil support members. It comprises a plurality of coils, the plurality of coils are divided into a plurality of sets consisting of a plurality of coils in a predetermined positional relationship, the coils in each set are connected in series with each other, and the coils in each set are connected in series with each other. In a stator for a step motor in which lead wires are connected to the last coil, the plurality of coils in each group are all wound with one continuous coil wire, and the middle part of the coil wire is connected to the coil wire in each group. extending between each coil, each coil in each set being connected in series by an intermediate portion thereof, and adjacent to said first and last coil of the coils in each set; A plurality of terminal housings are disposed thereon, each terminal housing comprising a cavity receiving a terminal, an outer wall facing radially outwardly of the core, and an inner wall facing radially inwardly of the core. the outer wall and the inner wall thereof each have a coil wire insertion slot, and the end of the coil wire on the first coil side extends from the inner wall side of the terminal housing adjacent to the first coil. extending through the coil wire insertion slot in the inner wall, across the cavity to the coil wire insertion slot in the outer wall, terminating in the coil wire insertion slot, and received within the cavity of the terminal housing. is electrically connected to a terminal, and the end of the coil wire on the last coil side passes through the coil wire insertion slot in the inner wall from the inner wall side of the terminal housing adjacent to the last coil. extending across the cavity to the coil wire insertion slot in the outer wall, terminating in the coil wire insertion slot, and electrically connected to a terminal housed in the cavity of the terminal housing; In the method for manufacturing a stator in which the lead wires are connected to the respective terminals, each of the terminal housings is attached onto the core, and a coil wire is drawn out from a coil wire supply source to connect one of the plurality of coil sets. After passing the coil wire from the outer wall side of the terminal housing adjacent to the first coil of the set through the coil wire insertion slot in the outer wall, the cavity, and the coil wire insertion slot in the inner wall. , after winding the first coil, further extending the coil wire to wind each coil in the set, and winding the last coil in the set, the inside of the terminal housing adjacent to the last coil; the coil wire insertion slot in the inner wall from the wall side;
The coil wire is passed through the coil wire insertion slot in the outer wall of the first terminal housing of the next coil set, the cavity and the inner wall. After passing through the coil wire insertion slots, all the coils of the set are wound and recirculated through the coil wire insertion slots of the inner wall of the terminal housing, the cavity, and the outer wall of the terminal housing adjacent to the last coil of the set. Winding all the coils of all sets with one continuous coil wire so as to pass through the coil wire insertion slot,
A portion of the coil wire that extends between the terminal housings without passing through the coil is selectively cut, a terminal is inserted into the cavity of each terminal housing, and a portion of the coil wire that crosses the cavity. A method characterized by electrically connecting the terminal to the terminal, and further connecting a lead wire to the terminal. 9. The method according to claim 8, wherein the cutting of the coil wire and the insertion of the terminal are performed substantially simultaneously.