JPH11289724A - Stator of rotary electric machine and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the productivity of a stator with a main coil and a shunt coil by fixing a ball core to a yoke in advance and at the same time successively winding the shunt coil being connected in one piece around two ball cores, and then winding the main coil around a plurality of ball cores. SOLUTION: Four ball cores 3 are fixed to the inner wall of a yoke 2, are arranged at an equal interval in the periphery direction of the yoke 2, are composed of a core part 3a and a collar part 3b, and a shunt coil and a main coil 5 are wound around the core part 3a. A covering electric wire where one electric wire is covered with an insulation covering is used for the shunt coil, and the covering electric wire is continuously and successively wound around each of the ball cores 3. Also, a covering electric wire where a plurality of electric wires are bundled and are covered with an insulation film covering is used for the main coil 5, and the covering electric wire is wound on the upper layer of the shunt coil of each of the ball cores 3 by a specific number of turns.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a stator for a rotating electric machine and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in a stator of a small DC motor such as a starter motor, a field coil (hereinafter, referred to as a "starter motor") has been used in order to prevent mechanical damage (for example, damage to a pinion gear of a starter) due to abnormal high speed rotation during no-load operation. In addition to a main coil), there is known a structure having a compound winding type coil provided with an auxiliary shunt coil (hereinafter referred to as a shunt coil) (for example, refer to Japanese Patent Application Laid-Open No. 63-154055).

[0003]

However, the conventional compound-wound coil structure has a problem due to its structure. Hereinafter, conventional steps and problems will be described. First, the same number of winding bobbins as the number of poles of the stator are prepared. Subsequently, the main coil and the shunt coil are sequentially wound on the same bobbin using a winding device. At this time, it is necessary to pull out the ends of each winding (the beginning and the end of the winding) to the outside of the bobbin. Assuming that the number of poles of the stator is N, the number of terminals is 2 (main shunt) × 2 (start and end of winding) × N = 4N. Subsequently, the bobbin after winding is mounted on a single pole core (pole core before being fixed to the yoke), and the pole core on which the bobbin is mounted is fixed to the yoke by screwing or caulking. In the case of winding on the bobbin (indirect winding) in this way, it is necessary to separate the winding step on the bobbin from the mounting step of the bobbin. Need to be kept.

Subsequently, in order to connect the terminals of each winding to form a predetermined electric circuit, each terminal is electrically connected to each predetermined position using a connection bar. In general, a shunt coil uses an extra fine wire for a main coil, and therefore, its reliability is important when connecting to a connection bar. For this reason, it is extremely important to reduce the number of connection points. However, when winding is performed using a bobbin, the number of connection points cannot be reduced because the shunt coil must be divided into poles inevitably. For this reason, the connection work between the shunt coil and the connection bar becomes complicated, and a work space for connecting each of the main coil and the shunt coil wound for each bobbin with a crossover becomes extremely small. as a result,
The difficulty of the connection work increases, and automation is difficult, so that manual work is required. Therefore, there is a problem that reliability and productivity are reduced. In addition, it is extremely troublesome to reliably inspect the performance of each of the main coil and the shunt coil, so that it is difficult to perform an electrical inspection method of a finished product.

The above problem is a problem derived from indirectly winding a shunt coil and a main coil on a bobbin in advance. As a means for solving this problem, a method of directly winding each coil around a pole core is considered. However, the specific winding method has not been realized. The reason is that technical means for solving the problem that occurs when each coil is directly wound on the pole core has not been established yet. Issues in winding each coil directly to the pole core are listed. In the winding order of the shunt coil and the main coil,
The optimal order in terms of winding efficiency and terminal processing is unknown. It is unknown how to prevent breakage and damage of the crossover between the poles of the shunt coil. In the terminal processing, it is not known how to reduce the number of joints and the workability of the connection work. The optimal product configuration, process, and inspection method for mass production are unknown. The present invention has been made based on the above circumstances, and an object of the present invention is to provide a stator manufacturing method capable of improving the reliability and productivity of a stator including a main coil and a shunt coil,
An object of the present invention is to provide a stator manufactured by the manufacturing method and an inspection method capable of reliably performing an electrical inspection of an electric circuit.

[0006]

(Means for Solving the Problems) In a state in which the pole core is fixed to the yoke in advance, a shunt coil connected to one pole is sequentially wound around at least two pole cores, and then the main coil is wound. Is wound around a plurality of pole cores. Note that the shunt coil may be wound on at least two pole cores even when the pole core has four or more pole cores. Of course, it goes without saying that winding may be performed on all pole cores. In this case, since the shunt coil thinner than the main coil is wound before the main coil, the crossover of the shunt coil is firmly held between the main coil wound on the upper layer of the shunt coil and the inner wall of the yoke. Structure. Thereby, disconnection of the shunt coil in which one ultrafine wire is wound in multiple layers can be prevented, and a stator excellent in vibration resistance can be provided. In addition, by winding the shunt coil and the main coil directly on the pole core previously fixed to the yoke, it is possible to provide an inexpensive stator with high working efficiency, easy automation, and low cost.

After the shunt coil and the main coil are wound around the pole core, the terminal holding means is attached to one open end of the yoke in a state where the respective shunt coils and the main coil are drawn out. Mounting, subsequently electrically connecting the shunt coil to the shunt terminal held by the terminal holding means, and electrically connecting the main terminal to the main coil,
By electrically connecting the + side shunt terminal and the + side main terminal to the terminal connecting means, and electrically connecting the-side shunt terminal to the yoke, each connection processing of the shunt coil and the main coil can be performed. It can be performed reliably and a highly reliable stator can be provided.
It is needless to say that the terminal holding means for holding the shunt terminal insulates between the + side shunt terminal and the − side shunt terminal and between the + side shunt terminal and the yoke. That is, the terminal holding means is preferably formed of an insulating material such as a thermoplastic resin, and a conductive material may be used as long as the surface is subjected to an insulating treatment.

The + side shunt terminal has a joint joint with the terminal connecting means and a joint joint with the shunt coil, and the minus side shunt terminal has a joint joint with the yoke. And a joint joint part of the shunt coil. As a result, it is possible to provide a stator having high reliability of individual connection portions and high vibration resistance.

The shunt terminal on the negative side is electrically connected to one open end face of the yoke. This makes it possible to easily connect the yoke to the ground without modifying the insulating structure.

First, after electrically connecting the main terminal to the main coil, an insulation state between the main coil and the yoke is checked, and then the shunt coil is electrically connected to the shunt terminal. After connecting to the yoke, the insulation between the shunt coil and the yoke is inspected. Subsequently, after electrically connecting the negative shunt terminal to the yoke, the insulation between the main coil and the yoke is again inspected. Then, after electrically connecting the + side shunt terminal and the + side main terminal to the terminal connecting means, a short circuit test between the main coil and the shunt coil is performed.
Also, the resistance value of the main coil and the resistance value of the shunt coil are inspected. By performing each inspection according to the above-described procedure, it is possible to reliably detect defects relating to the grounding, short circuit, and resistance value of the main coil and the shunt coil, so that a high-quality and highly reliable rotor can be provided.

[0011]

Next, an embodiment of the present invention will be described with reference to the drawings. (First Embodiment) FIG. 1 is an upper plan view seen from the axial direction of a stator. The stator 1 of this embodiment is provided in a DC motor such as a starter motor, for example, and includes components described below [a yoke 2, a pole core 3 (3A to 3D), a shunt coil 4, a main coil 5, and a bushing.・ Insulation 6, Shunt terminal 7 (7A, 7B),
Main terminal 8 (8A, 8B), connection bar 9, lead wire 10, brush 11, etc.]. Since the structure of the DC motor other than the stator 1 is very well known, the description is omitted.

A) Yoke 2 A yoke 2 is formed of a ferromagnetic material such as iron or steel and has a cylindrical shape (see FIGS. 4 and 5). b) Pole Cores 3 As shown in FIG. 4, a predetermined number (four in this embodiment) of pole cores 3 are fixed to the inner wall of the yoke 2, and each pole core 3
Are arranged at equal intervals in the circumferential direction of the yoke 2. The pole core 3 includes a core 3a and a flange 3b (magnetic pole piece), and a shunt coil 4 and a main coil 5 are wound around the core 3a. c) Shunt coil 4 The shunt coil 4 uses a covered electric wire in which one electric wire is covered with an insulating film, and the covered electric wire is successively wound around each pole core 3 sequentially (see FIG. 3). d) Main coil 5 The main coil 5 uses a covered electric wire in which a plurality of electric wires are bundled and covered with an insulating coating, and the covered electric wire is used as each pole core 3.
Is wound around the upper layer of the shunt coil 4 (see FIG. 3).

E) Bushing insulation 6
(Hereinafter, abbreviated as insulation 6) An annular component that holds the shunt terminal 7, and is attached to the inner periphery of one open end of the yoke 2. As shown in FIG. 6, the insulation 6 has a main coil lead-out portion 6a for drawing out a lead wire of the main coil 5 and a shunt coil lead-out portion for drawing out a lead wire of the shunt coil 4, as shown in FIG. 6b are formed. In addition, each of the coil drawers 6a and 6b has
As shown in (1), a tapered portion 6c for guiding the lead wires of each of the coils 4, 5 may be provided. The insulation 6 is mounted on the yoke 2 and has a positive shunt terminal 7A and a negative shunt terminal 7A.
In order to maintain B, an insulating material is preferable, and a thermoplastic resin is particularly preferable. However, even a conductive material can be used if the surface is subjected to insulation treatment.

F) + side shunt terminal 7A A component which is connected to the lead wire (terminal) of the shunt coil 4 drawn from one coil lead portion 6b of the insulation 6 and electrically connects with the connection bar 9. As shown in FIG. 10, connection means (two fitting holes 7a in FIG. 10) for connecting the base 70 to the insulation 6, a connection joint 7b to the connection bar 9, and connection to the shunt coil 4 A joint 7c is provided. The + side shunt terminal 7A is made of a conductive material such as iron or copper (copper is optimal), and
It is preferable to perform plating (tin plating is optimal) in order to improve the weldability. Although the joint joint 7c with the shunt coil 4 shown in FIG. 10 is opened in a substantially V shape, it may be provided in a flat plate shape as shown in FIG. Further, as shown in FIG. 12, a joint 7d for temporary holding may be provided in addition to the joint 7c.

G) -Shunt terminal 7B A component that is connected to the lead wire (terminal) of the shunt coil 4 drawn from the other coil lead portion 6b of the insulation 6 and makes an electrical connection with the yoke 2. ,
As shown in FIG. 13, a connecting means (two fitting holes 7 a in FIG. 13) for connecting the base 6 to the insulation 6, a joint 7 e to the yoke 2, and a joint 7 f to the shunt coil 4. Is provided. The negative side shunt terminal 7B is made of a conductive material such as iron or copper (copper is optimal), and is preferably subjected to plating (tin plating is optimal) to improve the weldability with the yoke 2. The thickness of each of the shunt terminals 7A and 7B on the + side and the-side may be set to (wire diameter of the shunt coil 4) x (0.6 to 0.9).

H) + side main terminal 8A These parts are respectively provided on the lead wires of the main coil 5 drawn out from the two coil lead portions 6a of the insulation 6, and make electrical connection with the connection bar 9. , Made of a conductive material such as iron or copper, and formed in a substantially U-shape (see FIG. 33). i) Negative side main terminal 8B Other two coil extraction portions 6 of insulation 6
A component that is provided on the lead wire of the main coil 5 drawn out from a and makes electrical connection with the brush 11, is made of a conductive material such as iron or copper, and is formed in a substantially U shape ( See FIG. 33).

J) Connection bar 9 This is a terminal connecting component for electrically connecting the two + side main terminals 8A and the + side shunt terminal 7A (see FIGS. 1 and 3). The connection bar 9 is made of a conductive material such as iron or copper (copper is optimal), and is preferably subjected to plating (tin plating is optimal) in order to improve weldability with the terminals 8A and 7A. k) Lead wire 10 A lead wire 10 for supplying electric energy from a battery (not shown) to the electric circuit of the stator 1. One end is connected to the positive electrode of the battery, and the other end is connected to the connection bar 9. (See FIGS. 1 and 3). 1) Brush 11 A current path between the stator 1 and the rotor is formed by sliding the commutator surface of the rotor (not shown).

Next, the electric circuit of the stator 1 (the connection structure between the shunt coil 4 and the main coil 5) will be described with reference to FIG. FIG. 3 is an example of a development view when the stator 1 is viewed from the inner diameter side. Connection structure of shunt coil 4 Lead wire 10 → connection bar 9 → + side shunt terminal 7A → lead wire 4a of shunt coil 4 → winding counterclockwise with respect to first pole core 3A → crossover wire 4b → second wire Winding clockwise to the pole core 3B → crossover wire 4c → winding counterclockwise to the third pole core 3C → crossover wire 4d → fourth pole core 3D
Winding clockwise to shunt → Lead wire 4e of shunt coil 4
→ Shunt terminal 7B → Ground to yoke 2. Connection structure of main coil 5 Lead wire 10 → connection bar 9 → + side main terminal 8A (2 pieces) → first
And the third and third pole cores 3A and 3C are wound counterclockwise and the second and fourth pole cores 3B and 3D are turned clockwise to the right-side main terminal 8B (two pieces) → brush 11 → commutator. Through to the rotor.

Subsequently, a processing apparatus for manufacturing the stator 1 of the present embodiment will be described. The processing device is the work W
Pallet 12 (see FIG. 14) for mounting (workpiece) and transporting between each process, winding machine 1 for shunt coil 4
3 (see FIG. 15), a winding machine 14 for the main coil 5 (see FIG. 1).
7), terminal processing device 15 for shunt coil 4 (FIG. 1)
9). a) Pallet 12 The pallet 12 is, as shown in FIG.
0, a work holding unit 121, and a terminal holding unit 122 for the shunt coil 4. The base unit 120 functions as a guide unit when moving on a manufacturing line (see FIG. 21).

The work holding portion 121 is provided in a cylindrical shape on the base portion 120, and receives the other opening side (lower end portion in FIG. 2) of the yoke 2 inside the cylinder to receive the yoke 2
(Work W) is held. The terminal holding means 122 is for holding the lead wires (the start wire and the end wire) of the shunt coil 4 wound on the pole core 3, and the base portion 12 near the lead wire of the shunt coil 4 is pulled out.
0 are provided at two places. This terminal holding means 122
For example, a mechanism for holding (gripping) the lead line using elasticity is preferable. In addition, the terminal holding means 122 is provided with an upper opening of the work W (yoke 2) held by the work holding portion 121 so that the lead wire of the shunt coil 4 held does not obstruct the work in each step. It is better to provide it at a lower position.

B) Winding machine 13 of shunt coil 4 As shown in FIG. 15, the winding machine 13 includes a tension generator 130, a winding device 131, a nozzle 132, a terminal processing mechanism 133, a pallet moving mechanism 134, Winding pack 13
5 and so on. The tension generator 130 can generate a predetermined tension on the electric wire D. The winding device 131 includes a path (not shown) for supplying the electric wire D to the nozzle portion 132 and a cam mechanism (not shown) substantially similar in shape to the brim portion 3b of the pole core 3. It rotates at high speed while following a trajectory that roughly follows the circumference. As shown in FIG. 16, the nozzle part 132 includes one winding nozzle 136 on the side surface of the nozzle part 132, and the nozzle part 132 rotates on the inner peripheral side of the pole core 3. By supplying the electric wire D to the magnetic pole portion of the pole core 136, the efficiency at the time of winding can be increased.

The terminal processing mechanism 133 includes the shunt coil 4
Is a mechanism for holding the terminal (the winding start line and the winding end line) on the terminal holding means 122 of the pallet 12, and can perform each operation of raising, lowering, and rotating in addition to holding the terminal. The pallet moving mechanism 134 has a function of rotating the pallet 12 to a predetermined position and a function of moving the pallet 12 during winding processing and terminal processing.
It has the function of descending. The winding pack 135 is a pack for supplying electric wires, and accommodates the electric wires D for the shunt coil 4 inside. This winding machine 13 includes a winding device 131
The relative positions of the pole cores 3 and the winding nozzles 136 with respect to the axis of the yoke 2 are determined in cooperation with the pallet moving mechanism 134, and as shown in FIG. By performing the rotation operation following the shape of the brim portion 3b of the pole core 3, the coil can be wound around a predetermined pole core 3.

C) Winding machine 14 of main coil 5 As shown in FIG. 17, the winding machine 14 includes a tension generating device 140, a winding device 141, a nozzle section 142, a terminal processing mechanism 143, a pallet moving mechanism 144, Winding pack 14
5 and so on. The tension generator 140 can generate a predetermined tension on the electric wire D. The winding device 141 includes a path (not shown) for supplying the electric wire D to the nozzle portion 142, and a cam mechanism (not shown) substantially similar to the brim portion 3b of the pole core 3, and the periphery of the brim portion 3b is substantially formed. It rotates at high speed while following the trajectory to follow. As shown in FIG. 18, the nozzle portion 142 includes a plurality of (two in FIG. 18) wound nozzles 146 on a side surface of the nozzle portion 142, and the nozzle portion 142 rotates on the inner peripheral side of the pole core 3. On the other hand, the winding nozzle 146 connects the electric wire D to the pole core 3.
The efficiency at the time of winding can be increased by supplying to the magnetic pole portion.

The terminal processing mechanism 143 is a mechanism for holding a terminal (a winding start line and a winding end line) of the main coil 5 and performing a predetermined processing operation. Pallet moving mechanism 144
Has a function of rotating the pallet 12 to a predetermined position, and a function of raising and lowering during winding processing and terminal processing. The winding pack 145 is a pack for supplying electric wires,
An electric wire D for the main coil 5 is housed inside. The winding machine 14 includes a winding device 141 and a pallet moving mechanism 14.
The position of each pole core 3 and the winding nozzle 146 relative to the axis of the yoke 2 is determined in cooperation with the yoke 2, and the nozzle portion 142 is moved by the cam mechanism of the winding device 141 to the pole core 3 as shown in FIG. By performing a rotation operation following the shape of the brim portion 3b, winding can be performed around a predetermined pole core 3.

D) Terminal processing device 15 of shunt coil 4 This terminal processing device 15 temporarily fixes the terminal of the shunt coil 4 held by the terminal holding means 122 of the pallet 12 to the shunt terminal 7 assembled to the work W. As shown in FIG. 19, it is composed of a machine base 150 on which the pallet 12 is mounted, a terminal distribution arm 151, a terminal positioning mechanism 152, a terminal caulking mechanism 153, and the like. The terminal distribution arm 151 is connected to the pallet 12
The terminal of the shunt coil 4 held by the terminal holding means 122 is gripped and arranged at a predetermined position of the shunt terminal 7 assembled to the work W. Since the terminal distributing arm 151 requires a complicated operation,
It is composed of a multi-axis robot and a combination of multiple loaders.

The terminal positioning mechanism 152 is a mechanism for finally positioning the terminal of the shunt coil 4 to a predetermined position. That is, since the terminal distributing arm 151 grips and distributes the terminal of the shunt coil 4, the position of the terminal root of the shunt coil 4 temporarily fixed to the shunt terminal 7 becomes unstable. Therefore, the terminal positioning mechanism 15
By 2, the terminal root of the shunt coil 4 is positioned and inserted into the root holding part of the shunt terminal 7. The terminal caulking mechanism 153 is for temporarily fixing (caulking) the terminal base of the shunt coil 4 to the shunt terminal 7.

Next, a manufacturing process of the stator 1 will be described with reference to FIGS. FIG. 20 is a process block diagram for explaining the process order, and FIG. 21 shows a production line in which the respective processes are continuously arranged and the conveyance between the respective processes is automated. It is a conceptual diagram of the manufacturing process performed. The production line shown in FIG. 21 is provided with a conveying means V (for example, a belt) for conveying the pallets and a circulating means (not shown) for circulating the pallets (empty state) after the processing is completed. Step 001: A cylindrical yoke 2 is formed by cutting a pipe-shaped material, or by drawing or rounding with a press. Step 002: Core part 3 by cutting, cold forging, pressing, etc.
Then, a pole core 3 including the a and the flange 3b is formed. Step 003: The pole core 3 is fixed to the inner wall of the yoke 2 held by the work holding portion 121 of the pallet 12 by screwing, caulking, welding or the like (see FIG. 22). Step 004: An insulating structure is formed on the inner wall of the yoke 2 and the winding portion (core portion 3a) of the pole core 3. For example, an insulating structure may be formed by using powder coating or mounting a resin bobbin on the pole core 3 before fixing the pole core 3 to the yoke 2.

Step 005: The winding start line 4a of the shunt coil 4 is drawn out by a predetermined length in advance by the winding machine 13, and then the shunt coil 4 is continuously wound around each of the pole cores 3 (3A to 3D). The winding end wire 4e is drawn out by a predetermined length. The winding process of the shunt coil 4 is shown in FIGS. Both ends 4a and 4e of the shunt coil 4 can be pulled out by a predetermined length by a drawing mechanism (not shown) provided in the winding machine 13. In this winding step, tension is applied to the electric wire D when winding on each pole core 3 so that the crossover of the shunt coil 4 can escape to the inner wall side of the yoke 2 when the main coil 5 is wound. When laying the wires, loosen the tension and allow the crossover wires to have slack. Alternatively, tension is applied to each of the pole cores 3 when the winding is completed, the tension is loosened after the predetermined winding is completed, the winding nozzle 136 is rotated in the reverse direction, and then the rotation is performed again (this causes slack in the electric wire). And then distribute the crossover. After the winding of the shunt coil 4 is completed, the winding start wire 4a and the winding end wire 4e of the drawn shunt coil 4 are held by the terminal holding means 122 of the pallet 12 (see FIG. 25).

Step 006: The main coil 5 is wound on the upper layer of the shunt coil 4 by the winding machine 14. When winding the main coil 5, first, winding is performed on two opposing pole cores 3 at the same time, and then a lead wire 5 a having a predetermined length is formed. Winding is performed simultaneously. The winding process of the main coil 5 is shown in FIGS. Note that the lead wires 5a and 5b of the main coil 5 can be drawn out by a predetermined length by a drawing mechanism (not shown) provided in the winding machine 14. In this winding step, the shunt coil 4 is mounted so that the crossover of the shunt coil 4 already wound does not interfere with the nozzle portion 142 of the winding machine 14 (particularly, the winding nozzle).
A means for releasing the crossover to the inner wall side of the yoke 2 is used. Means for releasing the crossover include, for example, a guide arrow having a leading end on the inner diameter side from a place where the crossover of the shunt coil 4 is provided, and an upper opening of the yoke 2 when the main coil 5 is wound. The main coil 5 and the shunt coil 4 are inserted by inserting a guide arrow
Interference with the crossover can be prevented. After the guide arrow is inserted into the yoke 2 from the upper opening of the yoke 2, the guide arrow is expanded toward the inner wall of the yoke 2, thereby preventing interference between the main coil 5 and the crossover of the shunt coil 4. You can also.

Step 007: After completion of the winding of the main coil 5 (see FIG. 29), as shown in FIG. 30, the lead wires 5a and 5b of the main coil 5 are twisted by several turns to be integrated. Step 008: As shown in FIG. 31, the insulation 6 is mounted (assembled) on the inner periphery of one open end of the yoke 2. At this time, the lead wires 4a, 4e of the shunt coil 4
The lead wires 5a and 5b of the main coil 5 are drawn from a coil drawer 6b and a coil drawer 6a formed on the insulation 6, respectively. Step 009: The shunt terminals 7 (two) are fixed to the insulation 6 attached to the yoke 2. As a fixing means for fixing the shunt terminal 7 and the insulation 6, for example, as shown in FIG.
A circular fitting hole 7a is formed in the base portions 70, 71 of A, 7B, and the protrusion 6d is fitted into the fitting hole 7a, and the fixing can be performed by heat caulking. Alternatively, both may be fixed with an adhesive, or the metal shunt terminal 7 may be integrally formed with the resin insulation 6 by insert molding or the like. Each shunt terminal 7 may be held (fixed) on the insulation 6 in advance before the insulation 6 is mounted on the yoke 2.

Step 010: Lead wire 5 of main coil 5
a, 5b are fixed by the insulation 6. Here, a U-shaped collar portion is provided in the insulation 6, a lead wire of the main coil 5 is inserted into the collar portion, the inlet portion of the collar portion is heat-sealed, and the main coil 5 is closed by ultrasonic swaging or the like. 5 Leader wire is fixed. Thereby, the vibration resistance of the lead wire of the main coil 5 can be improved. Step 011: A main terminal (referred to as a hoop material) 8 is formed in a substantially U-shape from a steel material, copper, a copper alloy, or the like (see FIG. 33). Step 012... As shown in FIG. 33, the main terminal 8 is attached to the connection portions of the lead wires 5 a and 5 b of the main coil 5 with the connection bar 9, and caulked and temporarily fixed.

Step 013: The main terminal 8 is energized and heated to melt the insulating coating of the main coil 5, and the coating is peeled off to make electrical connection between the main terminal 8 and the main coil 5. Here, since an extra line is formed above the main terminal 8, the lead wires 5a and 5b of the main coil 5 are cut to predetermined dimensions as necessary (see FIG. 34). At this time, if the width dimension of the main terminal 8 is set to a predetermined dimension in advance so that the main terminal 8 is not cut at the time of cutting off the extra line, the life of the cutting cutter can be extended. Step 014: The resistance value between the two main terminals 8 on the + side or the − side is measured, and the main coil 5 is measured based on the measured value.
The insulation state between the motor and the yoke 2 is determined.

Step 015: Both ends of the shunt coil 4 held by the terminal holding means 122 of the pallet 12 are detached from the terminal holding means 122 and are temporarily held by a holding mechanism provided on the insulation 6 (see FIG. 35). ). As shown in FIGS. 36 and 37, for example, the insulation 6 includes a groove 6e for inserting a lead wire base of the shunt coil 4, and a lead wire base of the shunt coil 4 inserted into the groove 6e. A holding mechanism including a holding piece 6f for temporary holding is provided. The operation when the leader of the shunt coil 4 is held by the holding mechanism will be described with reference to FIG. With the holding piece pressing means 16 pressing the holding piece 6f to increase the opening width of the groove 6e, the coil end pressing means 17 inserts the base of the lead wire of the shunt coil 4 into the groove 6e. Next, the holding piece pressing means 16 is retracted to release the pressing force on the holding piece 6f, so that the holding piece 6f returns to the original position by the elastic force and the shunt coil 4 inserted into the groove 6e is pulled out. Hold the root of the wire. FIG. 38 shows a step of holding the base of the lead wire of the shunt coil 4 connected to the + side shunt terminal 7A. The case of holding is performed in the same manner.

Step 016: The connecting joints 7c and 7f provided on the shunt terminal 7 are caulked to fix the base of the lead wire of the shunt coil 4 temporarily held by the holding mechanism of the insulation 6. The joint joints 7c and 7f of the shunt terminal 7 are
Are provided in a V-shape which is larger than the wire diameter of the shunt coil 4. Folded portions 7c1 and 7f1 for preventing the shunt coil 4 from collapsing are provided at one end of the V-shape. Here, by pressing the side where the folded portions 7c1 and 7f1 of the joints 7c and 7f are provided and closing the opening of the V-shaped portion, the base of the lead wire of the shunt coil 4 can be caulked and fixed. . Step 017: As shown in FIG. 39, electric current is applied to the joint 7c of the + side shunt terminal 7A through a pair of electrodes 18 and 19 to heat and melt the coating of the shunt coil 4, and the electric wire of the shunt coil 4 and the shunt terminal 7 is electrically connected. The extra line of the shunt coil 4 generated in this step is cut to a predetermined size. Although FIG. 39 shows the + side shunt terminal 7A side, the same operation is performed on the − side shunt terminal 7B side.

Step 018: Two shunt terminals 7
The resistance between A and 7B is measured, and the insulation state between the shunt coil 4 and the yoke 2 is determined from the measured value. Step 019... Connect the ground connection portion (connection means to the yoke 2) of the − side shunt terminal 7 B to the spigot end of the yoke 2 by resistance welding, brazing, or the like. Step 020: A resistance value between the two main terminals 8 on the + side or the − side is measured, and the main coil 5 is determined from the measured value.
The insulation state between the motor and the yoke 2 is determined. Step 211: Connection bar 9 is formed into a predetermined shape (semicircular in this embodiment) from a conductive material such as iron, copper, or aluminum.
Mold into Step 022... As shown in FIG.
Is attached to the yoke 2. Here, the lead wire 10 connected to the connection bar 9 may be connected by welding or the like before mounting the connection bar 9 to the yoke 2 or may be connected after mounting the connection bar 9 to the yoke 2. Is also good. Step 023: The plus side shunt terminal 7A and the two plus side main terminals 8A are mechanically and electrically connected to the connection bar 9 by welding, brazing, or the like.

Step 024: A brush 11 is formed by sintering the connection wire 11a from powdery carbon / copper powder or the like. Step 025: The brush 11 is mechanically and electrically connected to the minus main terminal 8B by welding or brazing. Step 026: A resistance measuring element is brought into contact with both ends of the brush 11 or the main terminal 8 to measure the resistance value between the brushes 11 or the main terminal 8, and the resistance value of the main coil 5 becomes a predetermined value. Inspect that you are.
In this case, voltage drop measurement may be used instead of measuring the resistance value. Alternatively, a calculation device for measuring the temperature of the work W and performing temperature correction may be provided.

Step 027: + side shunt terminal 7A
The contact point for resistance measurement is brought into contact with the base portion 120 of the negative side shunt terminal 7B and the base portion 120 of the negative side shunt terminal 7B.
The resistance between the two shunt terminals 7 is measured to check that the resistance of the shunt coil 4 has a predetermined value. Step 028: In order to detect an interlayer rare short (short circuit) between the main coil 5 and the shunt coil 4, the probe of the impulse test is brought into contact with the base 120 of the + side shunt terminal 7A and the base 120 of the − side shunt terminal 7B. Then, an impulse voltage is applied between both the + side and the − side shunt terminals 7, and comparison with a non-defective product is performed. This makes it possible to detect minute defects that cannot be detected by resistance measurement, and to provide a high quality stator 1. Note that this step is performed as necessary, particularly when the durable life is required or when the stator 1 flows a large current.

(Effect of this embodiment) Stator 1 of this embodiment
Since the shunt coil 4 thinner than the main coil 5 is wound around the pole core 3 and the main coil 5 is wound above the shunt coil 4, the crossover of the shunt coil 4 is It is a structure that is firmly held between the inner wall and the inner wall. Thereby, disconnection of the shunt coil 4 in which one extra fine wire is wound in multiple layers can be prevented, and the stator 1 excellent in vibration resistance can be provided. Further, by directly winding the shunt coil 4 and the main coil 5 on the pole core 3 previously fixed to the yoke 2, the working efficiency is high and automation is easy, so that the inexpensive stator 1 can be provided. it can.

After the shunt coil 4 and the main coil 5 are wound around the pole core 3, the main coil 5 formed by collecting a large number of thin wires and the shunt coil 4 having only one thin wire are formed.
Can be sequentially and reliably connected by using the main terminal 8 and the shunt terminal 7, so that the highly reliable stator 1 can be provided. + Side shunt terminal 7
A has a joint 7b with the connection bar 9 and a joint 7c with the shunt coil 4, and the-side shunt terminal 7B has a joint 7e with the yoke 2 and the shunt coil 4. Since the joining joint 7f is provided, it is possible to provide the stator 1 having high reliability of individual connection parts and high vibration resistance. Further, since the minus side shunt terminal 7B is electrically connected to one opening end face of the yoke 2, it is possible to easily join the yoke 2 to the ground without modifying the insulating structure of the yoke 2.

In this embodiment, after the main terminal 8 is electrically connected to the main coil 5, the insulation between the main coil 5 and the yoke 2 is checked, and then the shunt coil 4 is connected to the shunt terminal 7. After electrical connection,
The insulation between the shunt coil 4 and the yoke 2 is inspected, and then the − side shunt terminal 7B is connected to the yoke 2.
To the main coil 5 and the yoke 2 again.
After checking the insulation state between the main coil 5 and the shunt coil 4 after electrically connecting the + side shunt terminal 7A and the + side main terminal 8A (two) to the connection bar 9, , And the resistance of the main coil 5 and the resistance of the shunt coil 4 are inspected. By inspecting the electric circuit according to this procedure, it is possible to reliably detect defects relating to the ground, short circuit, and resistance of the main coil 5 and the shunt coil 4, thereby providing a high-quality and highly reliable rotor.

After the shunt coil 4 is wound around the pole core 3, the crossover of the shunt coil 4 is released to the inner wall side of the yoke 2, so that the winding nozzle of the winding machine 14 is wound when the main coil 5 is wound. Interference with the crossover of the shunt coil 4 can be prevented. Pull out the winding start line and winding end line of the shunt coil 4 by a predetermined length, and connect both ends to the pallet 1
By holding the main coil 5 around the pole core 3, the shunt coil 4 can be prevented from being entangled by being held by the second terminal holding means 122. Main coil 5
In the winding step, the winding operation can be speeded up and the productivity can be improved by simultaneously winding the two opposing pole cores 3 and then simultaneously winding the next two opposing pole cores 3 .

(Second Embodiment) In this embodiment, an electrical connection method between the shunt terminal 7 and the shunt coil 4 will be described. FIG. 41 is a plan view showing a method of connecting the shunt terminal 7 and the shunt coil 4, and FIG. 42 is a side view. As shown in FIG. 41, the shunt terminal 7 is provided with a flat joint joint portion 7 c wider than the wire diameter of the shunt coil 4. The shunt coil 4
A predetermined terminal is arranged near the joint 7c of the shunt terminal 7 without peeling off the film, and is electrically connected to the joint 7c by a welding machine described below. As shown in FIGS. 41 and 42, the welding machine includes a joint joint 7c.
And an electrode 21 for pressing the joint 7c, and an electrode 22 for generating heat before pressing. With this welding machine, the coating of the shunt coil 4 is heated and melted, the coating is peeled off, and the shunt terminal 7 is removed.
The electric connection between the shunt terminal 7 and the shunt coil 4 is performed by pressurizing and energizing the joint joint portion 7c and the electric wire of the shunt coil 4.

(Third Embodiment) In this embodiment, a method for holding the base of the lead wire of the shunt coil 4 will be described. FIG. 43 is a plan view showing a method of holding the base of the lead wire of the shunt coil 4, and FIG. 44 is a side view. In this embodiment, as shown in FIGS. 43 and 44, after the lead wire 4a of the shunt coil 4 is held by the joint 7c of the + side shunt terminal 7A, the opening formed in the insulation 6 is removed. The base of the lead wire of the shunt coil 4 is maintained by being sealed with a resin 23 (UV resin, an adhesive or the like is optimal). In addition, the number 24 in the figure is a nozzle for sealing the resin. FIGS. 43 and 44 show the + side shunt terminal 7A, but the same can be applied to the − side shunt terminal 7B.

[Brief description of the drawings]

FIG. 1 is a plan view showing a structure of a stator.

FIG. 2 is a longitudinal sectional view showing a structure of a stator.

FIG. 3 is a conceptual diagram of an electric circuit according to the present embodiment.

FIG. 4 is a plan view showing a yoke and a pole core.

FIG. 5 is a longitudinal sectional view showing a yoke and a pole core.

6A is a plan view of an insulation, and FIG.

FIG. 7 is a partial plan view of an insulation showing a coil drawer;

FIG. 8 is a partial plan view of an insulation showing a coil drawer;

9A is a partial plan view of an insulation showing a coil lead-out portion, and FIG. 9B is a side view.

FIG. 10 is a three-view drawing of a + side shunt terminal.

FIG. 11 is a three-view drawing of a + side shunt terminal (another example 1).

FIG. 12 is a three-view drawing of a + side shunt terminal (another example 2).

FIG. 13 is a three-view drawing of a negative side shunt terminal.

14A is a plan view of a pallet, and FIG.

FIG. 15 is a schematic diagram showing a configuration of a shunt coil winding machine.

FIG. 16 is a perspective view showing a winding step of the shunt coil.

FIG. 17 is a schematic diagram showing a configuration of a main coil winding machine.

FIG. 18 is a perspective view showing a winding step of a main coil.

FIG. 19 is a schematic diagram showing a configuration of a terminal processing device for a shunt coil.

FIG. 20 is a process block diagram illustrating a process order of the present example.

FIG. 21 is a conceptual diagram of a manufacturing process according to the present embodiment.

FIG. 22 is a perspective view showing one process of a production line.

FIG. 23 is a plan view showing a state at the start of winding of the shunt coil.

FIG. 24 is a plan view showing a state at the end of winding of the shunt coil.

FIG. 25 is a perspective view showing a winding step of the shunt coil.

FIG. 26 is a plan view showing a state at the start of winding of a main coil.

FIG. 27 is a plan view showing a state in the middle of winding of a main coil.

FIG. 28 is a plan view showing a state at the end of winding of a main coil.

FIG. 29 is a perspective view showing a winding step of a main coil.

FIG. 30 is a perspective view showing a terminal processing step of a main coil.

FIG. 31 is a perspective view showing a step of assembling the insulation.

FIG. 32 is a plan view showing a state where the shunt terminal is fixed to the insulation.

FIG. 33 is a perspective view showing a step of assembling the insulation.

FIG. 34 is a perspective view showing a state where the main terminal is assembled.

FIG. 35 is a perspective view showing a terminal arranging step of the shunt coil.

FIG. 36 is a plan view showing a terminal holding mechanism (+ side) of the shunt coil.

FIG. 37 is a plan view showing a terminal holding mechanism (− side) of the shunt coil.

FIG. 38 is an operation explanatory view of a terminal holding mechanism (+ side) of the shunt coil.

FIG. 39 is a plan view showing a step of joining the shunt coil and the + side shunt terminal.

FIG. 40 is a perspective view showing a step of assembling the connection bar.

FIG. 41 is a plan view showing a step of joining the shunt coil and the + side shunt terminal (second embodiment).

FIG. 42 is a side view showing a joining step of the shunt coil and the + side shunt terminal (second embodiment).

FIG. 43 is a plan view showing a fixed method of fixing a terminal root portion of a shunt coil (third embodiment).

FIG. 44 is a side view showing a method of fixing the terminal root of the shunt coil (third embodiment).

[Explanation of symbols]

Reference Signs List 1 stator 2 yoke 3 pole core 4 shunt coil 5 main coil 6 bushing / insulation (terminal holding means) 6a main coil drawer 6b shunt coil drawer 7 shunt terminal 7b Joint joint part with shunt coil of plus side shunt terminal 7e Joint joint part with yoke of minus side shunt terminal 7f Joint joint part with shunt coil of minus side shunt terminal 8 Main terminal 9 Connection bar (terminal connecting means) D Electric wire

Claims (5)

[Claims] 1. A cylindrical yoke, a plurality of pole cores provided inside the yoke, a main coil wound directly on the pole core, and a wire thinner than the main coil, which is directly connected to the pole core. A shunt coil to be wound, wherein the pole core is fixed to the yoke in advance, and the shunt coil connected to one pole is sequentially connected to at least two pole cores. A method of manufacturing a stator for a rotating electrical machine, comprising: winding the main coil around the plurality of pole cores after winding. 2. The stator according to claim 1, wherein the shunt terminal is a means for connecting the shunt coil, a main terminal is a means for connecting the main coil, and the stator is mounted on one open end of the yoke. A terminal holding means for holding the shunt terminal; and terminal connecting means for electrically connecting the + side shunt terminal and the + side main terminal, wherein the shunt coil and the main coil are connected to each other. Is wound around the pole core, and the terminal holding means is attached to one opening end of the yoke in a state in which the respective lead portions of the shunt coil and the main coil are pulled out. Electrically connecting the shunt coil to the held shunt terminal; and The main terminal is electrically connected to a negative coil. Subsequently, the shunt terminal on the + side and the main terminal on the + side are electrically connected to the terminal connection means, and the shunt terminal on the-side is connected to the terminal. The method according to claim 1, wherein the stator is electrically connected to the yoke. 3. The stator according to claim 2, wherein the shunt terminal on the plus side includes a joint joint with the terminal connecting means, and a joint joint with the shunt coil. A stator for a rotating electrical machine, wherein the shunt terminal includes a joint joint with the yoke and a joint joint with the shunt coil. 4. The stator according to claim 2, wherein the negative side shunt terminal is electrically connected to one opening end face of the yoke. 5. The method for manufacturing a stator according to claim 2, further comprising the steps of: detecting a failure of an electric circuit; first, electrically connecting the main terminal to the main coil; And inspecting the insulation state between the yoke and, subsequently, after electrically connecting the shunt coil to the shunt terminal, inspecting the insulation state between the shunt coil and the yoke, After the shunt terminal on the negative side is electrically connected to the yoke, the insulation state between the main coil and the yoke is inspected again. Subsequently, the shunt terminal on the + side is connected to the terminal connecting means. After electrically connecting the main terminal on the side, the short-circuit inspection between the main coil and the shunt coil, and the resistance value of the main coil and the A method for manufacturing a stator of a rotating electric machine, comprising inspecting a resistance value of the shunt coil.