JPH05122910A - Manufacture of motor - Google Patents

Abstract

PURPOSE:To improve workability in accordance with mechanical insertion and also enhance economization and reliability by folding and bonding both ends portions of a plurality of arcuated phase-to-phase insulation plates to form a conic ring type phase-to-phase insulation member, forming projection region at the internal diameter side of the bonding portion and then inserting such projection region between the coils of different phases so that the internal diameter side is set on the side of a stator core. CONSTITUTION:A phase-to-phase insulation plate 9 is formed as a semi-circular ring type flat plate surrounding the external circumference and internal circumference, an inernally projecting projection region 6' in the internal diameter side is respectively provided at both ends of such insulation plate 9 and this plate 9 is bend with inclusion of the projection region 6'. Two-phase-to-phase insulation plates 9 are bonded at the bending portions to form a conic ring type phase-to-phase insulation member 10. The bonding portion 11 of this insulation plate 10 is located at the inter-pole area of the already inserted first-phase coil 2, the projection region 6 is engaged with the upper groove of a wedge guide and it is simultaneously inserted together with a second phase coil 3 by a mechanical inserter. Since the projection region 6' is engaged at the right angle with the upper groove of the wedge guide, it is not easily bent and it has sufficient strength, ensuring excellent workability because two sheets of insulation material is joined.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an electric motor, and more particularly to interphase insulation of an electric motor for electrically insulating between different phase windings of coil ends of a stator winding thereof.

[0002]

1 to 4 show a conventional apparatus, of which FIG. 1 is a development view of a stator using an interphase insulating plate 4, in which a first core coil 2 and a second phase coil are mounted on a stator core 1. 3, the annular interphase insulating plate 4 shown in FIG. 2 is mounted between the coil ends of the coils 2 and 3. The interphase insulating plate 4 is for each coil 2,
3 has a role of preventing contact with the coil end and increasing reliability of insulation resistance.

3 and 4 show a state in which the interphase insulating plate 4 and the second phase coil 3 are mechanically inserted.
Is inserted by the mechanical inserter when the second phase coil 3 is inserted.
The first phase coil 2 together with the second phase coil 3 from the direction of the arrow
And the second phase coil 3 are inserted. At this time, the inner diameter side protrusion 6 of the interphase insulating plate 4 is engaged with the upper groove of the wedge guide 7, and as the wedge guide 7 rises, the first phase coil 2 and the second phase coil 3 in the lead wire side coil end portion are separated. In between, the interphase insulating plate 4 is mounted so that the inner diameter side thereof is located on the upper side in FIG. 3 and FIG. 4, that is, on the side of the stator core 1.
At this time, the interphase insulating plate 4 is on the lower side in FIG. 3 with the outside of the notch 5 on the outer diameter side closed and overlapping, and the first annular interphase insulating plate 4 is generally cylindrical after mounting. Becomes In addition, 8 is a wire guide blade.

[0004]

The above-mentioned conventional device has the advantage that the interphase insulating plate 4 can be mechanically inserted simultaneously with the coil 3, but has the following drawbacks. That is, the interphase insulating plate 4 has a thin initial shape (0.
(About 125-0.3 mm) Because it is a planar annular shape,
When the inner diameter side protrusion 6 is engaged with the upper groove of the wedge guide 7 during machine insertion, the mechanical strength is not sufficient only by the thickness necessary for interphase insulation, and the wedge guide easily bends during insertion. There was a defect that it was dropped from No. 7, and was not fully inserted into the space between the coil ends of the coils 2 and 3. Also, in order to have sufficient strength to prevent the above-mentioned fall-off, it is uneconomical because a thickness of about twice the thickness required for insulation is required, and in this case the radial shape is applied to the outer diameter side during machine insertion. However, there is a drawback that cracks are likely to form from the bottom of the notch 5 provided in the. Moreover, the material of the interphase insulating plate 4 that is usually used is easily charged with static electricity.
When stacking and picking up one sheet from each other, the workability is poor because they are attracted to each other by static electricity.
It is easy to set more than one sheet on the machine inserter at the same time. In this case as well, if the bottom of the notch 5 is cracked or the number of coils 2 and 3 to be inserted is large, the machine inserter is locked during the ascent. It has a drawback that causes troubles in the manufacturing process, such as being done.

The present invention has been made in order to eliminate the above-mentioned conventional drawbacks, and can be inserted into a machine correctly and with good workability, and the plate thickness of the insulating material can be thin, which is economical and reliable. It is an object of the present invention to provide a high electric motor manufacturing method.

[0006]

According to the method of manufacturing an electric motor of the present invention, both ends of a plurality of arc-shaped interphase insulating plates are folded and sequentially joined to form a conical annular interphase insulating member. A protrusion is formed on the inner diameter side of the joint portion of the interphase insulating member, and the interphase insulating member is inserted between the different phase windings of the electric motor so that the inner diameter side is the stator core side.

[0007]

In the method of manufacturing an electric motor according to the present invention, the shape of the interphase insulation is changed step by step.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 5 shows the interphase insulating plate 9. The interphase insulating plate 9 is a semi-circular flat plate of approximately 180 ° surrounded by an outer circumference circle and an inner circumference circle, and the inner circumference side length is the circumference of the inner circumference. It is formed so that the length of the outer circumference is less than half and the length of the outer circumference is less than half of the circumferential length of the outer circumference, and both ends thereof are provided with protrusions 6 ′ protruding inward on the inner diameter side, respectively. Bend from the dotted line position including the part 6 '. The inner diameter of the interphase insulating plate 9 is slightly larger than the inner diameter of the stator core 1, and the outer diameter radius is approximately the inner diameter radius plus the coil end height of the coils 2 and 3. Further, a notch portion 5 is provided in the central portion of the interphase insulating plate 9 in the radial direction from the outer diameter side, the notch portion 5 is gradually widened toward the outer diameter side, and its bottom portion 5a is formed in an arc shape. .. Then, two interphase insulating plates 9 are provided, and the bent portions at both ends are overlapped with each other and heated by induction heating or the like to be joined, and the inner diameter side and the outer diameter side are not in a flat arc shape but three-dimensional. A substantially conical annular interphase insulating member 10 is formed. Reference numeral 11 denotes the joint portion, and the protrusion 6 ', that is, the inner diameter side is sufficiently joined, but the outer diameter side is not joined. In addition, the joint portion 11 projects outward.

FIG. 7 shows a state in which the interphase insulating member 10 having the above construction is mounted together with the second phase coil 3 by mechanical insertion, in which case the joint 11 is already inserted in the stator core 1 and the first phase coil 2 is inserted. So that it is located between the
Also, engage the protrusion 6 ′ with the upper groove of the wedge guide 7,
As in the conventional case, the mechanical inserter is used to simultaneously insert the second phase coil 3. The protrusion 6'is shaped to engage the upper groove of the wedge guide 7 at a right angle when set, and protrudes in a direction that is difficult to bend in the insertion direction. Also, since two insulating materials are stacked and joined together, insulation is achieved. The material has sufficient strength without increasing the thickness of the material more than necessary, and the interphase insulating member 10 does not fall off due to the bending of the projection 6'when the machine is inserted. Further, since the interphase insulating member 10 has a conical shape, it is easier to set it on the mechanical inserter as compared with the conventional planar annular member, and it is also easy to separate each one when attracted by static electricity. Furthermore, although the interphase insulating member 10 is finally mounted in a substantially cylindrical shape between the coil ends of the coils 2 and 3, the outer diameter side is closed by the notch 5 from the planar annular shape as in the conventional case. Compared with the cylindrical shape, the cutout portion 5 overlaps on the outer diameter side from the conical annular shape, and the joint portion 11 goes out to the outside of the interelectrode portion of the first phase coil 2 to form a closed cylindrical shape. The shape change is smooth and the thickness can be reduced, which reduces the load on the mechanical inserter at the time of insertion and enhances workability. At the same time, when inserting into the interphase insulating plate 10 and each coil 2,3. The damage done can be reduced.

In FIG. 8, the interphase insulating member 10 is attached to each coil 2, 3
Shows the state of being mounted between the coil ends on the lead wire side of
The joint portion 11 is located at the interelectrode portion of the first phase coil 2 to prevent contact between the interelectrode portions. In FIG. 8, the inter-pole portion of the first phase coil 2 is separated, but when a molding process is performed to reduce the outer dimensions of the coil end, the inter-pole portion is easily contacted and insulated by the protruding joint portion 11. A layer short circuit between poles is prevented. Further, the notch portion 5 overlaps with the hatched portion after mounting and is useful for deforming the interphase insulating member 10 into a cylindrical shape as in the conventional case. Of course, the interphase insulating member 10 serves to insulate the coil ends of the coils 2 and 3.

In the above embodiment, the interphase insulation intended for the two-pole motor has been described. However, if the interphase insulating plate 9 is made into a quarter ring shape and the joints 11 are provided at four places, four poles (concentric winding) are provided. It can be applied to an electric motor, or to a 6-pole electric motor if there are 6 places. Needless to say, if the number of joints is increased, the processing cost will be slightly increased, but the yield of material removal will be improved. Further, the interphase insulation between the first phase coil 2 and the second phase coil 3 has been described, but it goes without saying that it is also applicable to the interphase insulation between the second phase coil and the third phase coil.

As described above, in the present invention, the inwardly projecting projections are provided on the inner diameter side of both ends of the interphase insulating plate formed on the arc-shaped flat plate, and the both ends are bent together with the projections. Forming a substantially conical annular interphase insulating member by joining the bent portions of a plurality of interphase insulating plates, the interphase insulating member is inserted between the different-phase windings so that the inner diameter side is fixed and the core side is inserted. The two protrusions that engage with the upper groove of the wedge guide at the time of machine insertion are joined together so that they have sufficient strength without making the thickness thicker than the thickness required for insulation, and they do not bend when inserted. It does not fall off from the machine inserter and can be inserted correctly. In addition, it is economical because the plate thickness is thin. In addition, since the interphase insulating member has a conical annular shape, it is easy to set it on the mechanical inserter, and it is easy to separate it when a plurality of them are adsorbed by static electricity, and the deformation to the cylindrical shape at the end of mounting is smooth. It is possible to reduce the load on the interphase insulating member, each phase winding and the mechanical inserter at the time of insertion, so that the insertion workability can be improved and the insulation reliability can be improved.

[0013]

EFFECTS OF THE INVENTION Since the present invention is constructed as described above, the method of manufacturing an electric motor is economical and highly reliable because the insertion of the machine is correct and the workability is good, and the thickness of the insulating material may be thin. Is obtained.

[Brief description of drawings]

FIG. 1 is a development view of a stator of a conventional electric motor.

FIG. 2 is a plan view of a conventional interphase insulating plate.

FIG. 3 is a front view illustrating a conventional insertion work of an interphase insulating plate.

FIG. 4 is a perspective view of an essential part of FIG.

FIG. 5 is a plan view of an interphase insulating plate according to the present invention.

FIG. 6 is a front view of an interphase insulating member according to the present invention.

FIG. 7 is a front view illustrating an inserting operation of the interphase insulating member according to the present invention.

FIG. 8 is a perspective view of a coil end portion of the electric motor stator according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Stator core 2 1st phase coil 3 2nd phase coil 5 Notch part 5a Bottom part 6'Protrusion part 7 Wedge guide 9 Interphase insulating plate 10 Interphase insulating member 11 Joint part

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Shigeru Muramatsu Inventor Shizuoka City, 3-18-1, Oka Shizuoka Mfg. Co., Ltd. Shizuoka Factory

Claims (1)

[Claims] 1. A method for manufacturing an electric motor, wherein windings of an electric motor stator are subjected to interphase insulation between coil end different-phase windings, and projections inwardly protruding toward inner diameters of both ends of an arc-shaped flat plate. A step of forming a notch in the radial direction from the outer peripheral side of the central part to form the interphase insulating plate, and bending both ends of each of the plurality of interphase insulating plates including the protruding part, and sequentially bending the bent part. A step of forming a conical annular interphase insulating member by superposing and joining, and a step of inserting this interphase insulating member between winding phases so that the inner diameter side becomes the stator core side and finally becomes a cylindrical shape. A method of manufacturing an electric motor, comprising: