JPH082167B2 - Stator manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Object of the Invention (Field of Industrial Application) The present invention relates to a method of manufacturing a stator with improved means for changing the electromagnetic characteristics of the stator coil.

(Prior Art) Conventionally, for example, in a stator used in an axial gap type brushless motor, a plurality of stator coils formed by winding a conductive wire are arranged in an annular shape on an insulating substrate facing a permanent magnet of a rotor. . In this case, when the motor characteristic is changed, the number of windings of the stator coil is changed.

(Problems to be Solved by the Invention) However, in the above-described conventional configuration, stator coils having different numbers of windings must be prepared for different models having different motor characteristics. However, it was difficult to distinguish between the stator coils having different numbers of windings, and it was troublesome to manage the parts.

The present invention is intended to solve such a problem. Therefore, an object of the present invention is to provide a stator manufacturing method capable of sharing a stator coil for models having different motor characteristics and improving manufacturability and manageability of parts. To provide.

[Structure of the Invention] (Means for Solving Problems) According to the method for manufacturing a stator of the present invention, a molded product of a winding body formed by winding a conductive plate in a tubular shape is traversed across the winding body. A stator coil mold body formed by cutting, and a printed circuit board on which the mold body is arranged,
A characteristic is that a short-circuit conductor is formed on the printed board, and the short-circuit conductor is brought into contact with a cut end surface of a part of the winding layers of the stator coil to short-circuit the winding layers. .

(Operation) The cut end surface of the stator coil is exposed at the cut end surface of the mold body. Focusing on this point, the short-circuit conductor part formed on the printed circuit board is brought into contact with the cut end face of a part of the winding layers of the stator coil to short-circuit these winding layers. The electromagnetic characteristics of the stator coil can be changed by changing the size and position of the conductor portion.

(Embodiment) An embodiment in which the present invention is applied to a method for manufacturing an axial gap type brushless motor will be described below with reference to the drawings. First, in FIG. 7 showing the overall configuration, 1
Is a metallic printed circuit board that also serves as a stator yoke, and a bearing shaft 2 is provided in the center thereof. 3 is a molded body of the stator coil 4 mounted on the printed circuit board 1, which is a cut piece of a molded product 5 to be described later.
As shown in the figure, for example, four stator coils 4 arranged in an annular region are molded with a molding resin 6. Then, at the winding start end portion on the inner circumference side and the winding end portion on the outer circumference side of the stator coil 4, copper-shaped lead-out portions 7 and 8 are formed, respectively.
Are formed. On the other hand, although not shown, a wiring pattern is formed on the upper surface of the printed circuit board 1 via an insulating layer, and a solder resist layer 9 (see FIG. 3) is formed on the wiring pattern by, for example, printing to form the wiring pattern on the stator coil. Insulated from 4. Further, on the upper surface of the printed circuit board 1, connection pins 10 connected to the wiring pattern are provided so as to correspond to the respective lead-out portions 7 and 8 as shown in FIG. Therefore, the molded body 3 of the stator coil 4 is attached to the printed circuit board 1
In the state of being attached to, the connecting pins 10 of the printed circuit board 1 are inserted into the lead-out portions 7 and 8 of the stator coil 4 and are in a connected state with each other. Thus, a portion of the upper surface of the printed circuit board 1 corresponding to a part of the winding layer on the outer peripheral side of the stator coil 4 has a short-circuit conductor portion 11 (shaded lines) as shown in FIG. (Shown) is formed. The short-circuit conductor portion 11 is formed at the same time as the wiring pattern, and no solder resist layer is formed on the upper surface of the short-circuit conductor portion 11. As a result, the short-circuit conductor portion 11 comes into contact with the cut end face of a part of the winding layers on the outer peripheral side of the stator coil 4 to short-circuit these winding layers. Connection conductors 12 and 13 (shown with diagonal lines) are formed on the upper surface of the printed circuit board 1 corresponding to the protrusions 7 and 8, and the connection conductors 12 and 13 are formed on the connection conductors 12 and 13. The cut end faces of the protruding portions 7 and 8 are in contact with each other. In contrast to the stator 14 configured as described above, reference numeral 15 shown in FIG. 7 is a rotor, which has a rotating shaft 15a rotatably inserted through and supported by the bearing cylinder 2 and a rotor yoke 16 fixed to the upper end of the rotating shaft 15a. Fix the magnet 17 to the bottom surface of the
Are opposed to the stator coil 4 via a predetermined gap.

Now, referring to FIGS. 4 to 6, the stator coil 4 will be described.
A method of manufacturing the molded body 3 will be described. Reference numeral 18 is a winding core having a substantially triangular prism shape, and a storage hole 18a extending in the axial direction is formed at the center of the winding core.
And the storage hole 18a is opened to the outside by a slit 18b. A copper pipe 19 is accommodated in the accommodating hole 18a of the winding core 18, and the slit formed in the copper pipe 19
19a is aligned with the slit 18b of the winding core 18. On the other hand, 20
Is a conductive plate having an insulating layer (not shown) formed on one surface.
After one end of the conductive plate 20 is press-fitted into the slit 19a of the copper pipe 19 through the slit 18b of the winding core 18, the core 18 is
To form the winding body 21 (see FIG. 5). And the slit 22a of the copper pipe 22 similar to the copper pipe 19
Is press-fitted into the other end of the conductive plate 20. As a result, the winding body 21
The copper pipes 19 and 22 are provided in an electrically connected state at the winding start end and the winding end. Thereafter, only four winding bodies 21 thus formed are housed in a molding die (not shown) and arranged in a substantially annular shape by the positioning function of the molding die. Then, the openings at both ends of each of the copper pipes 19 and 22 are sealed with, for example, a part of the molding die so that the molding resin does not flow inside, and then the molding resin is injected into the molding die to be solidified. Thus, a molded product 5 having a shape such that four winding bodies 21 are inserted into the molded resin layer 23 is formed (see FIG. 6). Then, the mold is opened and the molded product 5 is taken out from the molding die.
6 is cut in a so-called sliced state so as to traverse the four winding bodies 21 as shown by broken lines in FIG. 6, so that the cut pieces of the winding bodies 21 serve as the stator coils 4 and the copper pipes 19,2.
A mold body 3 having the cut pieces 2 as the protrusions 7 and 8 is formed. The molded body 3 thus formed is attached to the printed circuit board 1, and the respective lead-out portions 7 and 8 are inserted into the connection pins 10 to be connected to each other, and the stator coil 4 is wound on the outer peripheral side. The cut end face of the layer is connected to the short circuit conductor portion 11 of the printed circuit board 1.
And the winding layers are short-circuited to complete the stator 14.

In the motor of FIG. 7 using such a stator 14,
When the stator coil 4 of the stator 14 is sequentially energized, a torque is generated due to the interaction with the magnet 17 of the rotor 15,
15 rotates. In this case, the short-circuit conductor portion 11 on the printed circuit board 1 is brought into contact with the cut end surface of the winding layer on the outer peripheral side of the stator coil 4 to short-circuit the winding layers. No current flows in the layer in the winding direction, the short-circuited portion becomes electromagnetically negligible, and the same electromagnetic characteristics as the number of windings of the stator coil 4 is reduced by the number of windings of the short-circuited portion. become. Therefore, in the case of the stator coil 4 of the present embodiment (a part of the winding layer is short-circuited by the short-circuit conductor portion 11), the starting current is reduced due to the reduction in resistance as compared with the case where the short-circuit conductor portion 11 is not provided. However, the motor characteristics are such that the starting torque is substantially the same and the no-load speed is high.

Therefore, in the present embodiment, when the motor characteristic (electromagnetic characteristic of the stator coil 4) is changed, the size of the short-circuit conductor portion 11 is appropriately changed according to the change, and the number of windings between the winding layers to be short-circuited is changed. Should be increased or decreased. Therefore, it is not necessary to change the number of windings of the stator coil 4 even for models having different motor characteristics, and the stator coil 4 can be shared. Moreover, the stator coil 4 is the molded product 5 of the winding body 21.
Since it is formed by cutting, the stator coil 4 is inherently excellent in manufacturability as compared with a conventional stator coil formed by winding a conductive wire, and the short-circuit conductor portion 11
Can be easily realized by changing the solder resist layer 9 formed on the printed board 1, and the short-circuit conductor portion 11 can be formed simultaneously with the wiring pattern. The manufacturability of can be improved. Moreover, since the number of types of parts (stator coils) is reduced by making the stator coil 4 common, part management becomes easier accordingly. Further, since the winding body 21 and thus the stator coil 4 are reliably positioned by the molding die having high accuracy, the positional accuracy of the stator coil 4 can be enhanced and torque ripple is prevented from occurring in the rotor 15 as much as possible. You can

In the above embodiment, the short-circuit conductor portion 11 short-circuits a part of the winding layer on the outer peripheral side of the stator coil 4, but on the contrary, short-circuits a part of the winding layer on the inner peripheral side. It may be configured to do so.

[Effects of the Invention] As is apparent from the above description, the present invention provides a short circuit formed on a printed circuit board on a cut end face of a part of a winding layer of a stator coil formed by cutting a molded product of a winding body. Since the winding conductors are brought into contact to short-circuit these winding layers, the motor characteristics can be changed by changing the size and position of the shorting conductor without changing the number of windings of the stator coil itself. Therefore, it is possible to share the stator coil even for models with different motor characteristics, and it is also possible to form the short-circuit conductor part at the same time as the wiring pattern, which improves manufacturability and parts management. It has an excellent effect of enhancing the property.

[Brief description of drawings]

The drawings show one embodiment of the present invention. FIG. 1 is an enlarged plan view of a stator coil portion, FIG. 2 is a cross-sectional view of a stator coil mold, and FIG. 3 is a printed circuit board and a mold. FIG. 4 is an exploded perspective view, FIG. 4 is a perspective view of a winding core, FIG. 5 is a perspective view of a winding body, and FIG. 6 is a perspective view of a molded product.
FIG. 7 is a vertical sectional view of the entire motor. In the figure, 1 is a printed circuit board, 3 is a molded body, 4 is a stator coil, 5 is a molded product, 11 is a short-circuit conductor portion, and 14 is a
Is a stator, 20 is a conductive plate, and 21 is a winding body.

Claims (1)

[Claims] 1. A stator coil mold body formed by cutting a molded body of a winding body formed by winding a conductive plate into a tubular shape so as to cross the winding body, and the molded body. A printed circuit board, a short-circuit conductor is formed on the printed circuit board, and the short-circuit conductor is brought into contact with a cut end surface of a part of the winding layer of the stator coil to short-circuit these winding layers. A method for manufacturing a stator characterized by the above.