JPH0588061B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a method for manufacturing a stator of a motor suitable for an axial gap type motor.

[Technical Background of the Invention] Conventionally, a stator used in, for example, an axial gap type brushless motor has an insulated conductor wire wound in advance into a predetermined shape on an insulated substrate facing a rotor equipped with a permanent magnet. It was manufactured by arranging a plurality of winding bodies in a ring shape and fixing them individually with adhesive.

[Problems with the Background Art] In the conventional manufacturing method described above, each winding body must be individually arranged and bonded on an insulating substrate, which causes problems such as time-consuming work and poor mass productivity. Since it is not possible to arrange and bond each winding body in a predetermined position with high precision, there is a problem that this causes torque ripple in the rotor.

[Object of the Invention] The present invention has been made in view of the above circumstances, and its purpose is to provide a method for manufacturing a stator of a motor that is excellent in mass productivity and that can prevent torque ripple in the rotor as much as possible. be.

[Summary of the Invention] The present invention involves winding a conductive plate into a cylindrical shape, and forming a plurality of winding bodies into an annular shape, each of which has a connection portion made of a conductive pipe extending in the axial direction at a winding start end and a winding end. These are then molded with insulating resin,
This integrally molded product is cut across the plurality of winding bodies to form a stator coil, and the stator coil is laminated on an insulating substrate having a protrusion at a position corresponding to the connection part of the stator coil. By fixing the stator coil, the process for extracting the stator coil is simplified, and the positional accuracy between the stator coil and the insulating substrate is improved.

[Embodiment of the Invention] Hereinafter, an embodiment in which the present invention is applied to an axial gap type brushless motor will be described with reference to FIGS. 1 to 6.

First, the overall configuration will be described based on FIGS. 1 and 2. 1 is a printed circuit board (insulating board) having a bearing sleeve 2 in the center, 3 is a stator coil manufactured as described later. Stator coil 3
For example, four windings 5 are arranged in a ring shape in a ring-shaped mold body 4 made of an insulating resin, for example, a polyimide resin, and are stacked and fixed on the printed circuit board 1. As shown in FIG. 2, of each winding 5 of the stator coil 3, the portion corresponding to the starting end of the winding on the inner circumferential side and the ending end of the winding on the outer circumferential side,
Copper outlet portions (connection portions) 6 each having an annular shape are formed. On the other hand, as shown in FIG. 3, the printed circuit board 1 has connecting pins 7 protruding from each of the openings 6 and connected to a wiring pattern (not shown).

Therefore, when the stator coil 3 is stacked on the printed circuit board 1, that is, assembled as a stator, the connecting pins 7 of the printed circuit board 1 are inserted into the openings 6 of the stator coil 3, and are connected to each other.

Reference numeral 8 denotes a rotor, which is composed of a rotor yoke 9 that is shaped like a flat circular container with an open bottom surface, and permanent magnets 10 that form magnetic poles are arranged around the inner circumference of the rotor yoke 9. A shaft 11 is provided protrudingly. The shaft 11 of the rotor 8 is inserted into and supported by the bearing sleeve 2 of the printed circuit board 1, so that the winding 5 and the permanent magnet 10 face each other with a predetermined gap. It's summery.

Now, a method for manufacturing the stator coil 3 will be described based on FIGS. 4 to 6. Reference numeral 12 denotes a substantially triangular winding core, and a storage hole 12a extending in the axial direction is formed in the center of the core.
is opened to the outside by a slit 12b which also extends in the axial direction. Storage hole 12a for core 12
A copper pipe 13 corresponding to the connection part is stored in the
A slit 13a formed in the copper pipe 13 is aligned with a slit 12b in the winding core 12. On the other hand, numeral 14 is a strip-shaped copper plate serving as a conductive plate on one surface of which an insulating layer (not shown) made of polyimide resin, for example, is formed. Pass one end of this strip-shaped copper plate 14 through the slit 12b of the winding core 12 and into the slit 1 of the copper pipe 13.
3a and wound around the winding core 12 a plurality of times to form the winding body 15 (see FIG. 5). Then, a copper pipe 16 having a slit 16a in the same way as the copper pipe 13 is connected so that the slit 16a is connected to the belt-shaped copper plate 14.
It is attached to the winding body 15 by being press-fitted into the other end. As a result, the copper pipes 13 and 16, which are conductive pipes that constitute the connection portion extending in the axial direction of the winding body 15, are electrically connected to the winding start end and the winding end of the winding body 15. It becomes the form provided in the state.

After that, only four of the winding bodies 15 formed in this way are housed in a mold (not shown), and the copper pipe 1 is
The molds are arranged in a substantially annular shape by the positioning function of the mold using the molds 3 and 16. Then, an insulating resin (not shown), such as a molten polyimide resin, is supplied into the mold and solidified, thereby forming the polyimide resin layer 1.
An integrally molded product 18 having four wire windings 15 inserted into the wire 7 is molded (see FIG. 6).
In this case, each copper pipe 13, 16 is sealed, for example, by a mold to prevent molten metal from flowing into the pipe.

Furthermore, this integrally molded product 18 is made to cross the four winding bodies 15 as shown by the broken line in FIG.
The four windings 5 are cut into so-called round slices with a thickness of 0.5 to 1.0 mm, and the four windings 5 are embedded in the mold body 4, and copper pipes 13 are placed at the winding start and end of each winding 5. , 16 are formed to complete the stator coil 3 having the outlet portion 6. Then, by a stator assembly mechanism (not shown), each outlet part 6 of the completed stator coil 3 is used as a positioning means, and the connecting pin 7 provided on the stator coil 1 is inserted into the outlet part 6, so that the stator is assembled. Assemble.

According to this embodiment, the following effects can be obtained. That is, a winding body 15 formed by winding a band-shaped copper plate 14 in a substantially triangular spiral shape is arranged in a substantially annular shape in a mold and molded with polyimide resin to form an integrally molded product 18. Since the stator coil 3 is manufactured by cutting the material 18 into circular slices, mass productivity is superior to that in the conventional case where winding wires are individually glued together. Moreover, since the winding body 15 is reliably positioned by a highly accurate mold, the winding 5 of the stator coil 3 is also inevitably positioned at the set position with high precision, and therefore the rotor 8 can be prevented as much as possible from causing torque ripple.

Furthermore, by appropriately setting the thickness dimension of the insulating layer of the strip-shaped copper plate 14, the conductor spacing of the winding 5 can be set arbitrarily and with high precision. By appropriately setting the thickness dimension of the 18 slices, the motor characteristics can be set arbitrarily. In addition, the winding body 15
Copper pipes 13, 1 are placed at the start and end of the winding.
6, an annular outlet portion 6 formed by cutting the copper pipes 13, 16 into rings is formed at the winding start end and the winding end of each winding 5 of the stator coil 3.

Therefore, if the connecting pin 7 corresponding to the outlet part 6 of the stator coil 3 is provided protrudingly on the printed circuit board 1, the stator coil 3 can be printed by using the outlet part 6 as a positioning means by the stator assembly mechanism. Just by stacking it on the printed circuit board 1, the outlet part 6 fits into the connecting pin 7 and an electrical connection is established, so the process of extracting the winding 5 is extremely simple, and furthermore,
It becomes possible to easily and accurately position the stator coil 3 and the stator coil 3.

Further, according to this embodiment, the connection portion between the winding start end and the winding end of the winding body 15 is connected to the copper pipes 13 and 1.
6, the connection part is connected to the winding body 15.
There is an advantage that the winding start end and the winding end can be formed by simply press-fitting the winding start end and winding end into the slits 13a and 16a of the copper pipes 13 and 16, respectively.

Furthermore, by constructing the connecting portion with copper pipes 13 and 16 that are separate from the strip-shaped copper plate 14 that constitutes the winding body 15, the strength of the connecting portion can be increased regardless of the thickness of the strip-shaped copper plate 14. There are also benefits that can be secured.

Furthermore, since the outlet part 6 has a ring shape formed by cutting the copper pipes 13 and 16, the connection state of the outlet part 6 can be directly inspected, and repair work can also be carried out using the holes in this ring. It can be done easily.

Moreover, since the excess solder used for connection can escape into the ring, lifting of the stator coil 3 from the printed circuit board 1 can be eliminated.

[Effects of the Invention] As explained above, the present invention includes a plurality of winding bodies arranged in a ring in a mold, molded with an insulating resin, and the integral molded product is cut to form a stator coil. This makes it easy to mass-produce,
The generation of torque ripple in the rotor can be prevented as much as possible, and since the connection parts made of conductive pipes are provided at the winding start end and winding end of the winding body, the winding opening can be prevented as much as possible. This greatly simplifies the process, and also makes it possible to easily form the connecting portion, as well as ensuring the strength of the connecting portion.

[Brief explanation of the drawing]

1 to 6 show an embodiment of the present invention,
Figure 1 is a vertical cross-sectional view of the entire brushless motor, Figure 2
The figure is a cross-sectional view of the stator coil, Figure 3 is a perspective view of the printed circuit board and stator coil, Figure 4 is a perspective view of the winding core, Figure 5 is a perspective view of the winding body, Figure 6 is a molded cigar hull. FIG. In the figure, 3 is a stator coil, 5 is a winding, 6 is an outlet, 7 is a connection pin, 8 is a rotor, 12 is a winding core,
13 and 16 are copper pipes (connecting parts), 14 is a strip-shaped copper plate (conductive plate), 15 is a winding body, and 18 is an integrally molded product.

Claims (1)

[Claims] 1. A conductive plate is wound into a cylindrical shape, and a plurality of winding bodies each having a connecting part made of a conductive pipe extending in the axial direction are arranged in a ring at the winding start end and winding end,
These are molded with insulating resin, and this integrally molded product is cut across the multiple winding bodies to form a stator coil, and a protrusion is formed at a position corresponding to the connection part of the stator coil. 1. A method of manufacturing a stator for a motor, comprising stacking and fixing the stator coil on an insulating substrate having a stator.