JPH0823653A - Stator winding and its manufacture - Google Patents

Abstract

PURPOSE:To prouide a srator winding by which the productivity of coil winding insertion work is improved, wrong fitting of coils is reduced, coil insertion is made easg, preheating for connection of coils and cooling after the connection are not needed to raise the productivity, influence of heat is eliminated, the reliability of the connection is improved, and deformation of the stator is prevented. CONSTITUTION:Coils 2 are formed by winding electric wires around bobbins in a plurality of layers and the coils 2 are inserted into a stator 1. Press- contacting connectors 4 are used for connecting the coils 2 to each other and connecting the coils 2 to lead wires 3. Molding jigs on both sides of the stator 1 are brought into contact with each other, but no molding force is applied to the stator 1 from the jigs.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor stator winding and a method for manufacturing the same. In particular, the present invention relates to a stator winding of a motor having a relatively low voltage and a high output, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Motors for electric vehicles have a battery voltage of, for example, 48 for an electric scooter in order to safely handle the battery and reduce the cost of the battery.
It is set to a relatively low voltage of V, and high output is required for the voltage. In the case of a general-purpose motor, the stator winding of the motor uses a coil having a large number of turns in which a thin electric wire is wound many times. On the other hand, since the motor for an electric vehicle has a low power supply voltage, the number of coil turns cannot be increased due to the back electromotive force. Therefore, the torque constant of the motor becomes small and the current flowing through the motor becomes large. Since it is necessary to pass a large current, the stator winding of the motor needs a coil in which a large number of electric wires are arranged in parallel in order to reduce heat generation.
However, the conventional technology has been developed with a focus on winding a thin electric wire a large number of times, and the technical development for a coil in which a large number of electric wires are arranged in parallel with a low turn number, which is suitable for a motor for an electric vehicle, has not been advanced. .

A side view of a conventional stator winding is shown in FIG. Reference numeral 21 is a stator, 22 is a coil, and 23 is a lead wire. Reference numeral 24 is a connecting portion between the coil and the lead wire, and 25 is a connecting portion between the coil and the coil.

In the conventional stator winding, one to six electric wires are wound at once by a winding frame to form a coil, and the coil is mounted on a winding inserter and inserted into the stator. When the number of electric wires is large, the coil wound with the winding frame was mounted on the winding inserter a plurality of times and then the coil was inserted into the stator. FIG. 6 shows a flow of manufacturing a conventional stator winding.
First, wind the wire around the reel. Next, the winding frame is disassembled and the coil is removed from the winding frame. Next, the coil is inserted into the jig of the winding inserter. The above work is repeated a predetermined number of times. Finally, the winding inserter is run to insert the coil into the stator slot.
In this way, the stator winding was manufactured.

In the coil-to-coil connecting portion 25, which is called a star connection or a Y connection, the electric wire is peeled off, the electric wires are twisted together, and then connected by soldering or welding.

The connecting portion 24 between the coil and the lead wire is also peeled off from the insulation film of the electric wire, and then the electric wires are twisted together to form a wire.
It was connected by soldering or welding.

After the coil is inserted into the stator, in order to shape the shape of the coil, when the coil is pressed by the forming jig to form the coil, the forming jig is received by the stator to position the forming jig. FIG. 7 shows a cross-sectional view of a conventional molding jig.
30 is an upper molding jig, and the tip portion 31 is made of metal in order to prevent abrasion. 32 is a lower molding jig, and the tip portion 3
3 is made of metal. When the upper and lower stator jigs are pressed from above, the molding jigs 30 and 32 directly contact the stator 21.

[0008]

However, after the coil wound by the winding frame is mounted on the winding inserter a plurality of times, the coil is mounted on the stator. In the manufacturing method, the coil is mounted on the winding inserter. Not only has the problem that it is time-consuming and that coil mounting mistakes are likely to occur, but also because the crossovers of the coil are intricately entangled, it is not possible to increase the number of coils so much, it is difficult to insert the coil, and the coil end It had the problem of getting bigger.

In a stator winding using soldering for coil-to-coil connection, if the number of electric wires is large, it takes time to preheat before soldering and cool down after soldering, and productivity is poor. However, there is a problem in that it is difficult to reliably solder the inside of the bundled electric wires, the reliability of the connection is poor, and the preheating causes the heat to affect the parts other than the connection part. Welding had the same problem.

The connection between the coil and the lead wire has the same problem.

When the coil is pressed by the forming jig to form the coil, the stator receives the forming jig and positions the forming jig. In the method of manufacturing the winding of the stator, the forming force is applied to the stator. Therefore, there is a problem that the stator 21 is deformed in the coil forming process as shown in FIG.

The object of the present invention is to eliminate the above-mentioned defects of the prior art to improve the productivity of coil winding insertion, reduce coil mounting errors, facilitate coil insertion, and eliminate the need for preheating and cooling during connection. The present invention provides a stator winding that improves the reliability, eliminates the influence of heat, improves the reliability of connection, and eliminates the deformation of the stator.

[0013]

A method for manufacturing a stator winding according to the present invention is a method for manufacturing a stator winding in which an electric wire is wound with a winding frame to form a coil, and the coil is inserted into a stator. It is characterized in that the coil is formed by winding the coil around the winding frame, and the coil is inserted into the stator.

The stator winding according to the present invention is characterized in that a crimp connector is used to connect the coils.

The stator winding according to the present invention is characterized in that a crimp connector is used for connecting the coil and the lead wire.

The method for manufacturing a stator winding according to the present invention is a method for manufacturing a stator winding in which a coil is inserted into a stator and then the coil is pressed by a molding jig to form the coil. It is characterized in that it abuts and the forming force is not applied to the stator from the forming jig.

[0017]

The method of manufacturing a stator winding according to the present invention is a method of manufacturing a stator winding in which an electric wire is wound with a winding frame to form a coil, and the coil is inserted into the stator. Since the coil was wound to form the coil and the coil was inserted into the stator, it was easy to mount the coil in the winding insertion machine, and the coil was not erroneously mounted. Further, since the crossovers of the coils do not entangle with each other in a complicated manner, the number of coils can be increased, the coil can be easily inserted, and the coil end can be reduced.

Further, since the stator winding according to the present invention uses the crimp connector for connecting the coils to each other, the preheating and cooling time required for soldering or welding is large even if the number of electric wires is large. Not only was it unnecessary, productivity was improved, the reliability of the connection was improved, and the problem of heat being exerted on the surroundings was completely solved.

Further, in the stator winding according to the present invention, since the crimp connector is used for connecting the coil and the lead wire, the preheating and cooling time required for soldering or welding even when the number of wires is large. Not only is not required, productivity is improved, connection reliability is improved, and the problem of heat being exerted on the surroundings is completely solved, and the lead wire is melted by the heat of the solder. Is gone.

Further, in the method for manufacturing a stator winding according to the present invention, in the method for manufacturing a stator winding in which the coil is inserted into the stator and then the coil is pressed by a molding jig, the molding jigs on both sides of the stator are Since the contact is made and the forming force is not applied to the stator from the forming jig, the forming force is not applied to the stator, and the problem that the stator is deformed in the coil forming process is solved.

[0021]

EXAMPLES A stator winding of a motor and a method for manufacturing the same will be described in detail based on examples below.

FIG. 1 is a side view of a stator winding according to an embodiment of the present invention. Reference numeral 1 is a stator, which is made by stacking 0.5 mm silicon steel plates. Reference numeral 2 denotes a coil, which is made by winding an electric wire called a magnet wire, which has an insulating coating on a copper wire. In the case of this embodiment, there are three single-phase Y-connections, one equivalent of four single coils, and one single coil has three turns. Since there are three-phase Y connections, there are three coils 2 for three phases. Φ of 20 parallel windings
A 0.8 mm wire was used for this stator winding. In order to facilitate the insertion of the wire into the stator 1, a surface-treated electric wire having low friction was used. The portion of the coil 2 extending from the stator 1 is called the coil end in order to distinguish it from the portion inside the stator 1. Reference numeral 3 is a lead line. This is also called a lead wire. In FIG. 1, only one lead line 3 is shown because the figure becomes complicated, but in reality, there are three lines for three phases. As the lead wire 3, a flame-retardant synthetic resin insulated wire having a nominal cross-sectional area of 5.5 square mm was used. Reference numeral 4 is a crimp connector for connecting the coils 2 to each other. Since the coil 2 has a three-phase Y connection, the crimp connector 4 connects the three-phase coil 2. Reference numeral 5 is a crimp connector for connecting the coil 2 and the lead wire 3.

FIG. 2 is a perspective view of a winding frame for winding the electric wire to form the coil 2. 6 is a frame around which the electric wire is wound.
7 is a spacer. Reference numeral 8 is a groove provided in the spacer 7 for providing a crossover portion in the coil 2. 9 is an axis. Reference numeral 10 is a nut. When the nut 10 is removed, the winding frame can be disassembled into pieces. The winding frame is a set of four coils for one phase of four coils. The winding machine is provided with six sets of coil bobbins and electric wire guides so that one to six electric wires can be simultaneously wound at one time. The winding frame rotates to wind the electric wire around the frame 6 to form the coil 2. The coil 2 is formed by winding 5 wires of φ0.8 mm three times at the same time on the frame 6 and further winding 3 times over the adjacent frame 6 through the groove 8 of the spacer 7, repeating this for 4 coils. A one-phase coil is completed. In the case of the conventional method, the nut is removed here, the winding frame is disassembled, the coil is removed from the winding frame, and the coil is mounted on the insertion jig of the winding insertion machine. In the case of the method of the present invention, the coil is not removed here, and the electric wire is already wound, and the above-described procedure is further repeated to overlap the electric wire and wind the electric wire around the winding frame. The formation of 5 coils each is repeated 4 times to obtain the desired 20 coils. In this way, the electric wires are overlapped a plurality of times and wound around the winding frame to form the coil 2, and then the winding frame is disassembled to remove the coil 2 from the winding frame, and the coil 2 is mounted on the insertion jig of the winding insertion machine.
Then, the winding inserter is operated to insert the coil 2 into the slot of the stator 1. This completes the coil insertion for one phase. FIG. 6 shows a flow of manufacturing the stator winding described above. First, wind the wire around the reel. This work is repeated a predetermined number of times. Next, the winding frame is disassembled and the coil 2 is removed from the winding frame. Then, the coil 2 is inserted into the jig of the winding inserter.
Finally, the winding inserter is operated to insert the coil 2 into the slot of the stator 1. In this way, the stator winding is manufactured.

As described above, the electric wires are stacked a plurality of times and wound around the winding frame to form the coil 2, and the coil 2 is inserted into the stator 1. Therefore, the number of times the winding frame is disassembled and the coil 2 is set in the winding insertion machine. The number of insertions into the jig has been reduced, improving productivity. Further, the coil 2 can be easily mounted on the jig of the winding insertion machine, and the coil 2 is less likely to be mounted incorrectly. Furthermore, since the crossover wires of the coil 2 do not entangle with each other in a complicated manner, the number of the coils 2 can be increased, the coil can be easily inserted, and the coil end can be reduced.

Y for connecting the coil 2 of each phase and the coil 2
Since it is necessary to connect 20 wires to each of the three connecting wires in three phases, it is necessary to connect 60 wires. Connection is made as follows. First, the lengths of 60 wires are trimmed, and then the insulation film of the electric wire of a predetermined length is peeled off. Insulating films were mechanically peeled off one by one using a film peeling machine to avoid problems of safety and pollution control. There are other methods for peeling the insulating film, such as using chemicals.
Next, an electric wire is put into the crimp connector 4, and the crimp connector 4 is caulked with a predetermined crimping tool. Finally, the crimp connection is covered with an insulating tube and fixed to the coil 2 with a thread or a binding band.
The crimp connector 4 is a JIS standard copper wire bare crimp sleeve P3.
8 was used. Since there are 60 electric wires having a diameter of 0.8 mm, the total cross-sectional area is about 30 square mm, and the coils 2 are reliably connected to each other by using the bare crimp sleeve P38 for copper wire.

Since the crimp connector 4 is used to connect the coil 2 to the coil 2 as described above, the preheating and cooling time required for soldering or welding is unnecessary even when the number of electric wires is large, and the production is not required. Not only has the reliability improved, but the reliability of the connection has also improved, and the problem of heat being exerted on the surroundings has been completely resolved.

The connection between the lead wire 3 of the motor and the coil 2 is performed as follows. 20 wires for one phase of the coil are cut and aligned, the insulating film is peeled off, the electric wire is put into the crimp connector 5, and the crimp connector 5 is caulked by a predetermined crimping tool. Next, the core wire of the lead wire 3 having a predetermined length stripped off is placed on the opposite side of the crimp connector 5, and the crimp connector 5 is caulked with a predetermined crimping tool. Finally, the crimp connection is covered with an insulating tube and fixed to the coil 2 with a thread or a binding band. Crimping connector 5 is J
A bare crimp sleeve P8 for IS standard copper wire was used. Diameter φ
The total cross-sectional area of 20 0.8 mm electric wires is about 10 square mm, and the coil 2 is reliably connected to the crimp connector 5 by using the bare crimp sleeve B8 for copper wire. Lead line 3
Has a nominal cross-sectional area of 5.5 mm 2, it is too thin for the bare crimping sleeve for copper wire B8, and a reliable connection cannot be obtained. Therefore, about half of the core wires of the lead wire 3 are cut into a predetermined length of 10 mm, and the other half are doubled in length.
Set to 0 mm, fold the double-length core wire, and crimp the connector 5
The portion to be inserted is doubled, and is crimped so that the cross-sectional area becomes about 8 square mm. In this way, since about half of the core wire is folded back to be doubled, the lead wire 3 is surely connected to the crimp connector 5. The coil 2 and the lead wire 3 are connected via a crimp connector 5.

Since the crimp connector 5 is used to connect the lead wire 3 and the coil 2 in this manner, even when the number of wires is large, the preheating and cooling time required for soldering or welding is unnecessary, Not only the productivity is improved, but also the reliability of the connection is improved, and the problem that the influence of heat is exerted on the surroundings is completely solved, and the lead wire 3 is not melted by the heat of the solder. .

FIG. 4 shows a sectional view of a coil end forming jig. Reference numeral 11 denotes an upper molding jig, which is made of plastic except for the tip portion shown at 12. The tip portion of 12 is made of metal to prevent abrasion. A lower molding jig 13 is made of plastic except for the tip portion 14 made of metal. Reference numerals 15 and 16 are engaging portions. When the upper and lower molding jigs 11 and 13 are pressed from above, the molding jigs 11 and 13 on both sides of the stator 1 are positioned such that the engaging portions 15 and 16 contact each other.
Even when 1 and 13 contact each other, the stator 1 and the molding jig 11 have a gap of about 0.2 mm to 1 mm. Therefore, the forming force for pressing the forming jigs 11 and 13 with a press or the like is not applied to the stator 1 from the forming jigs 11 and 13. The coil end is formed by forming the upper and lower forming jigs 11, 1.
At 3, insert the stator 1 with the coil 2 inserted,
It is done by pressing from above with a press. When the upper and lower forming jigs 11 and 13 are pressed by the press machine, the coil 2
Deforms following the shape of the molding jigs 11 and 13 to become a predetermined shape.

Since the stator 1 is made of a laminate of silicon steel plates, it is weak against the force in the direction in which the plates are displaced and is relatively easily deformed. Thus, the forming jigs 11 on both sides of the stator 1 are formed. , 13 are in contact with each other, and the forming force is not applied to the stator 1 from the forming jigs 11, 13, so that the forming force is not applied to the stator 1 and the stator 1 deforms in the coil forming process. Has been resolved.

The stator 1 whose coil end has been molded
Connect the coil 2 and the coil 2, connect the coil 2 and the lead wire 3, and then tie the coil end part with a thread,
Finally, varnish treatment is performed to complete the stator.

[0032]

As described above, since the electric wire is piled up a plurality of times and wound around the winding frame to form the coil, and the coil is inserted into the stator, the coil can be easily mounted on the winding insertion machine, It became difficult to make a mistake in wearing. Further, since the crossovers of the coils do not entangle with each other in a complicated manner, the number of coils can be increased, the coil can be easily inserted, and the coil end can be reduced.

As described above, since the crimp connector is used to connect the coils to each other, the preheating and cooling time required for soldering or welding is unnecessary even when the number of electric wires is large, and the productivity is improved. Not only did it improve the reliability of the connection, but it also completely solved the problem of being affected by heat.

As described above, since the crimp connector is used for connecting the lead wire and the coil, even when the number of electric wires is large, the preheating and cooling time required for soldering or welding is unnecessary, and the productivity is improved. Not only was it improved, but the reliability of the connection was also improved, and the problem of heat being exerted on the surroundings was completely solved, and the lead wire was no longer melted by the heat of the solder.

Since the forming jigs on both sides of the stator are in contact with each other and the forming force is not applied to the stator from the forming jig in this way, the forming force is not applied to the stator and the stator is deformed in the coil forming process. The problem of causing

[Brief description of drawings]

FIG. 1 is a side view of an embodiment of a stator according to the present invention.

FIG. 2 is a perspective view showing a reel according to an embodiment of the present invention.

FIG. 3 is a diagram showing a flow of manufacturing a stator winding according to an embodiment of the present invention.

FIG. 4 is a sectional view of a molding jig according to an embodiment of the present invention.

FIG. 5 is a side view of a conventional stator.

FIG. 6 is a diagram showing a flow of manufacturing a conventional stator winding.

FIG. 7 is a cross-sectional view of a conventional molding jig.

[Explanation of symbols]

 1 Stator 2 Coil 3 Lead wire 4 Crimp connector 5 Crimp connector 6 Frame 7 Spacer 8 Groove 9 Shaft 10 Nut 11 Forming jig 12 Tip part 13 Forming jig 14 Tip part 15 Engaging part 16 Engaging part

Claims (4)

[Claims] 1. A coil is formed by winding an electric wire with a winding frame,
A method for manufacturing a stator winding, wherein the coil is inserted into a stator, wherein the electric wire is superposed a plurality of times and wound around a winding frame to form a coil, and the coil is inserted into the stator. 2. A stator winding, wherein a crimp connector is used for connecting the coils to each other. 3. A stator winding, wherein a crimp connector is used to connect the coil and the lead wire. 4. A method of manufacturing a stator winding, comprising: forming a coil by pressing the coil with a forming jig after inserting the coil into the stator; A method for manufacturing a stator winding, which is characterized in that: