JPS6173552A - Manufacture of stator for motor - Google Patents

Abstract

PURPOSE:To obtain a stator having preferable characteristics and high productivity by integrally molding a winding unit wound with a conductive plate in a cylindrical shape and a waveshape arcuate unit with an insulating resin, slicing the molded unit to form a platelike stator. CONSTITUTION:A conductive plate is wound in a cylindrical shape to form a winding unit 4, and a plurality of the units 4 are annularly disposed. Further, after a waveshape arcuate unit 7 is disposed concentrically with the winding unit group, the winding unit group and the arcuate unit are integrally molded with an insulating resin to form a columnar molding unit. Then, the columnar unit is sliced at the section perpendicular to its axial direction in the prescribed thickness to form a platelike stator. The winding unit is used as a stator coil 3, and the arcuate unit is used as a frequency generating coil 7.

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, for example, in the stator of an axial gap type pushless motor, a frequency power generation coil p having a rectangular wave shape is formed on the upper region of the +F8 edge substrate by printed wiring means, and a ring shape concentric with the frequency power generation coil p on this insulating substrate is formed. A stator coil is formed by arranging a plurality of winding bodies each formed by winding an insulated conducting wire into a predetermined shape in advance and fixing them individually by adhesive.

[Problems with background technology]

In the above-mentioned conventional manufacturing method, 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 achieve high precision in arranging and gluing wires at set positions, the positional precision between each winding body is reduced, causing torque clip μ on the rotor. There is a problem in that the accuracy of concentricity with the generator coil is also reduced, which causes a reduction in the accuracy of rotor rotation detection.

[Purpose of the invention]

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a motor that is excellent in mass productivity, can prevent the occurrence of torque clip μ on the rotor as much as possible, and can improve the accuracy of rotor rotation detection. To provide a method for manufacturing a stator.

[Summary of the invention]

The present invention involves arranging a plurality of winding bodies formed by winding a conductive plate into a cylindrical shape in an annular shape, arranging an arcuate body forming a waveform in an annular area concentric with the group of winding bodies, and connecting these winding bodies with an insulating resin. and cutting the molded product into plate shapes across the winding body and the arc-shaped body to form a stator coil and a frequency power generation coil, respectively, by the crossed winding body and the arc-shaped body. The present invention is characterized in that, as a result, each winding body and the arcuate body can be positioned using a mold with high precision, and each winding body and the arcuate body can be integrally fixed.

[Embodiments of the invention]

An embodiment in which the present invention is applied to an axial gap type brushless motor will be described below with reference to the drawings. First, the structure of the stator A will be described based on FIGS. 1 to 5. Reference numeral 1 denotes a stator yoke.
is provided. Reference numeral 2 denotes a printed circuit board to which the bearing sleeve 1aK is fitted, and 3 a stator coil manufactured as described below.This is composed of, for example, four windings 4 arranged in a ring, each winding 4 having an insulating property. It is embedded in an annular mold body 5 made of resin, for example, polyimide resin. As shown in Figure tg2, an annular copper outlet 6 is provided at a portion corresponding to the inner winding start end and the outer winding end of each winding 4 of the stator coil 3, respectively. It is formed. Reference numeral 7 designates a frequency power generation coil manufactured as described below, which is arranged in an annular region on the outer peripheral side concentric with the fourth group of windings within the motor 21 body 5, and has an annular shape at each end thereof. A sunrise portion 8 made of copper is formed. On the other hand, as shown in FIG.
, 8 are formed, and a land (none of which is shown) continuous to the wiring pattern is formed at the periphery of the through hole 9.
is formed. Then, while the molded body 5 is stacked on the printed circuit board 2, the conductive eyelet 9a is attached to the opening part 6.
, 8 and the through hole 9 of the printed circuit board 1 and is fixed to the printed circuit board 2 by caulking. Therefore,
In this state, each outlet 6 of the stator coil/I/3 and both mouth ridges 8 of the frequency power generation coil/I/7 are electrically connected to the land by the eyelet 9a. On the other hand, the rotor B is constructed by disposing a field magnet 11 on the inner surface of a rotor yoke 10 in the shape of a flat circular container with an open bottom surface, and a ]-shaped frequency power generation magnet 12 on the outer circumferential surface of the rotor yoke 10. A shirt 10a is fitted in the center of the shirt 10. The shirt 10a is inserted into and supported by the bearing cylinder 1a of the printed circuit board 2, so that the winding 4, the field magnet 11, the frequency generating coil 1L/7, and the frequency generating magnet 12 are connected to predetermined positions, respectively. They face each other with a gap between them.

Now, based on FIGS. 4 to 7, the stator coil lV5
A method for manufacturing the frequency power generation carp/I/7 will be described.

Reference numeral 13 denotes a winding core having a substantially triangular prism shape, and a storage hole 13a extending in the axial direction is formed in the center of the core, and the storage hole 13& is opened to the outside through a slit 131) also extending in the axial direction. A copper pipe 14 is stored in the storage hole 13a of the winding core 13, and a slit 14a formed in the copper pipe 14
is made to coincide with the sleeve 13b of the winding core 13. on the other hand,
Reference numeral 15 denotes a strip-shaped copper plate, which is a conductive plate, on one side of which is formed an insulating layer (not shown) made of, for example, a polyimide surface layer.

Wrap one end of this strip copper plate 15: slit 1 of r513
31) is press-fitted into the sleeve 14a of the copper pipe 14, and wound around the winding core 13 a plurality of times. And the copper pipe 1
4 is press-fitted into the other end of the strip-shaped copper plate 15.

As a result, a winding body 17 is constructed in which mesh pipes 14 and 16 extending in the direction of the winding axis are electrically connected at the winding start end and the winding end (see FIG. 5). After this,
Only four of the winding bodies 17 formed in this manner are housed in a mold (not shown), and arranged in a substantially cylindrical shape using the positioning function of the mold.

- As shown in FIG. 6, an arc-shaped body 18 is formed by, for example, bending a corrugated copper plate into a substantially cylindrical shape. Then, the slits of the copper vibrator 19 are press-fitted into both radial ends of the arc-shaped body 18 in the same manner as described above. Thereafter, the arc-shaped body 1B is housed in the mold, and is arranged concentrically with the group of winding bodies 17 by the positioning function of the mold. Then, a molten insulating resin (not shown) such as a polyimide resin is supplied into the mold and solidified, and four winding bodies 17 and an arc-shaped body 18 are inserted into the polyimide resin layer 20. The molded product 21 is molded (see FIG. 7). In this case, each copper pipe 14, 16 .
19 is sealed by a mold, for example, to prevent molten metal from flowing into the inside. Furthermore, this molded product 21
As shown by the broken line in FIG. 8, the four winding bodies 17 and the arcuate body 18 are cut into a plate shape having a thickness of 0.5 to 1.0 mm in a so-called round cut state. The traversed polyimide resin layer 202 winding body 17. Arc-shaped body 18.
Mode p bodies 5. Each winding 42 of the stator coil 3 forms a frequency generating coil 7 and outlets 6, 8.

After that, as described above, the grist substrate 2 and the mold body 5 are
are stacked and fixed to each other with eyelets 9a, and
is completed.

According to this embodiment, the following effects can be obtained. That is, winding bodies 17 formed by winding belt-shaped copper plates 15 in a substantially triangular spiral shape are arranged in a substantially annular shape in a mold, and an arc-shaped body 18 that forms a waveform in an annular region concentric with the group of these winding bodies 17 is arranged. are arranged and mode-molded with polyimide resin to form a shell molded product 21, and this molded product 21 is cut into circular slices to produce a stator coil/I15 and a frequency power generation coil/I/7. I did it like this,
It is superior in mass production compared to the conventional case where winding wires are individually bonded. Moreover, since the winding body 17 and the arcuate body 18 are reliably positioned by a highly accurate mold, the positional accuracy between the windings 4 of the stator coil N5 and the concentricity of the winding 4 group and the frequency power generation coil/I/7 are ensured. Therefore, the occurrence of torque ripple in the rotor B can be prevented as much as possible, and the rotation detection accuracy of the rotor B can be improved.

Furthermore, by appropriately setting the thickness dimension of the insulating layer of the strip-shaped copper plate 15, the conductor spacing of the winding 4 can be set arbitrarily and with high precision. By appropriately setting the thickness dimension of the cross section 21, the motor characteristics can be arbitrarily set.

Furthermore, in this embodiment, the following additional effects can be obtained. Since the copper pipes 14, 16, and 19 are provided at the winding start end and winding end of the winding body 17 and at both ends of the arc-shaped body 18, the winding start end and the winding end of each winding 4 of the stator coil lv3 are provided. At the terminal end and at both ends of the arc-shaped body 18, annular openings 6, 8 are formed by cutting the copper pipes 14, 16, 19 into rings. Therefore, if the molded body 5 is stacked on the printed circuit board 2 and the stoppers 9a are passed through the openings 6, 8 and the through hole 9 of the printed circuit board 2 and caulked, the stator coil/V 5 and the frequency power generation coil/I/7 are connected. is printed circuit board 2
It is electrically connected to the land of and is firmly fixed to the printed circuit board 2. This is υ, stator carp/I
Soldering the /3 or frequency power generation carp /L/7 and the printed circuit board 2 can eliminate the need for mounting, and can also eliminate the need for an adhesive application process, which is different from the case of fixing with adhesive. This improves performance and makes it even more suitable for mass production.

In the above embodiment, the arcuate body 18 is formed into a substantially cylindrical shape so that its cross section is substantially circular, but the present invention is not limited to this.
For example, it may be formed into a curved shape, such as a half-cylindrical shape, whose cross section is a part of the circumference (arc). Further, the arc-shaped body 18 does not necessarily need to be formed by bending a corrugated conductor plate into a cylindrical shape, but may be formed by, for example, extrusion molding.

〔Effect of the invention〕

As explained above, the present invention consists of arranging a plurality of winding bodies in an annular shape, arranging an arcuate body having a corrugated shape in an annular region concentric with the winding bodies, and covering these with insulating l# resin. Since the stator coil and frequency power generation coil are formed by molding and cutting the molded product, mass production is excellent, and the positional accuracy of the stator coil and frequency power generation coil is improved, resulting in torque reduction in four days. This makes it possible to prevent the occurrence of clipping as much as possible, and also reduces the excellent effect of improving rotor rotation detection accuracy.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, in which FIG. 1 is a vertical cross-sectional view of the entire brushless motor, FIG. 2 is a cross-sectional view of the molded body,
Fig. 5 is an exploded perspective view of the printed circuit board and mold body, Fig. 4 is a perspective view of the winding core, Fig. 5 is a perspective view of the winding body, Fig. 6 is a perspective view of the arc-shaped body, and Fig. 7 is a perspective view of the winding core. FIG. 2 is a perspective view of a molded product formed by molding a wire body and an arc-shaped body. In the figure, 6 is a stator coil, 4 is a winding, 7 is a frequency power generation coil, 17 is a winding body, 18 is an arc-shaped body, 21 is a molded product, A is a stator, and B is a rotor. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Side 6 Figure 7

Claims (1)

[Claims] 1. A conductive plate is wound into a cylindrical shape to form a winding body, a plurality of these winding bodies are arranged in a ring shape, and an arc-shaped body forming a waveform is arranged in an annular area concentric with the group of winding bodies. These are molded with insulating resin, and the molded product is cut into plate shapes across the winding body and the arc-shaped body, and the crossed winding body and the arc-shaped body are used to generate stator coils and frequency power generators, respectively. A method of manufacturing a stator for a motor, characterized in that a coil is formed.