JPS62296733A - Manufature of stator of three-phase brushless motor and insulation plate of stator end surface - Google Patents

Abstract

PURPOSE:To facilitate motor assembly, by a method wherein a coil of each phase is wound in order without cutting, and crossover portion is cut into a phase leading portion. CONSTITUTION:When coils are wound, coils 17a, 17b in a first phase 17 from a winding start end 16, coils 18a, 18b in a second phase 18, and coils 19a, 19b in a third phase 19 are wound through crossover wires 23-1-23-3, 21 to a winding finishing end 20 in order without cutting at the midway. With respect to the coils 17a, 17b, the coils 18a, 18b are the same in winding number but reverse in winding direction, and the coils 19a, 19b are the same both in winding number and in winding direction. Next, the winding start end 16 is made a leading portion of the first phase 17, and the interphase crossover wire 22 is cut into a leading portion of the second phase 18 and the third phase 19, and the winding finishing end 20 is connected to the interphase crossover wire 21 to make the neutral point, thus coils of three-phase Y-connection are formed.

Description

Detailed Description of the Invention 3. Detailed Description of the Invention (Field of Industrial Application) The present invention relates to a three-phase brushless motor, and particularly relates to a three-phase brushless motor, in which a stator core having a plurality of teeth is insulated. This relates to a method of manufacturing a stator for a three-phase brushless motor in which a three-phase coil is wound directly around the stator of the motor, and an insulating plate on the end face of the stator used therein. It provides an optimal manufacturing method for motors, general-purpose motors, etc.

<Prior Art> FIG. 7 is a schematic explanatory diagram of a stator of a conventional three-phase brushless motor, where 1 indicates a stator core, and 2 and 3 indicate teeth. Electrical insulating material is interposed at the contact points between the stator core 1 and the coils and crossover wires between the coils, and generally, end face insulating plates made of resin molding are used on both axial end faces of the stator core and inside the slots. It is constructed by covering.

On the other hand, the winding of the coil is configured such that starting from the winding start end 4, winding a predetermined number of turns around the toothed portion 2, passing to the opposing toothed portion 3, winding the coil a predetermined number of times, and ending at the winding end 5.
The coil from the winding start end 6 to the winding end 7 and the coil from the winding start end 8 to the winding end 9 are similarly constructed. That is, each phase is wound independently. After that, 4,
The start end of each winding of 6.8 is connected to the outlet, and the end of each winding of 5.7.9 is connected to serve as a neutral point. Of course, the n-end of each of the windings may be used as the outlet, and the starting end of each winding may be used as the neutral point.

Figure 8 shows the coil outlet, the lead wires, and the method of connecting the coils to each other.
2a, 12b, and 12c are shown. After fixing this board 10 to the end of the coil using positioning parts provided on the end face insulating plate, the outlet part (for example, the winding start end) of each phase coil is printed at 4', 6', and 8°. The connection was completed by soldering to each pattern part, and soldering the other end of each phase coil (for example, winding n end) to the printed neutral point pattern part 11. That is, the lead wire and the coil were connected via the board 10.

FIG. 9 shows a wiring method that does not use the printed wiring board 10 described above, in which the lead wire 12 is wound around the outlet 30 of the coil and soldered, and the neutral point is connected (not shown). In this case, the winding ends or three winding beginning ends of each phase coil were twisted and then soldered.

FIG. 10 is a developed view showing the winding state of the coil shown in FIG. 7. All the coils wound around the teeth are wound a predetermined number of turns in the same direction, and after one coil of each phase is wound from the winding start end 4.6.8, each crossover wire +3
．． The other coil of each phase is wound through 14 and 15, and each winding ends at 5.7°9, forming a three-phase coil. Since these three sets of coils are wound at the same time, there are a total of six coil terminals.

<Problems to be solved by the invention> Thus, in the conventional manufacturing method, there are six coil terminals, so the coils loosen after winding and come off from the teeth, making them difficult to handle! ! There was a drawback that it became l. Furthermore, since the crossover wires of each phase always cross each other, the insulation between the crossover wires was insufficient, which could cause quality problems in those used at high voltages. Furthermore, the wiring method using a printed wiring board has traditionally been useful because the board can be used for positioning or fixing a rotor position detection sensor such as a Hall element. In so-called sensorless three-phase brushless motors that detect the rotor position, there is no need to mount a sensor, so using such a board only as a relay between the lead wire and the coil increases costs, and in recent years This has also been a hindrance to the particularly desired miniaturization of motors. Furthermore, even with a wiring method that does not use a printed circuit board, it requires a lot of manual work such as winding the coil outlet around the lead wire, connecting the three coil terminals that form the neutral point, and insulating and fixing the connection part. This required a lot of time and resulted in poor work efficiency.

Means for Solving the Problems> It is an object of the present invention to easily and completely insulate crossover wires without the wound coil becoming loose or coming off the teeth, and furthermore, The manufacturing technology is particularly suitable for sensorless three-phase brushless motors in which the housing is formed by molding, because the connection between the coil and the coil and the mutual connection of the coil terminals forming a neutral point and their fixing are easily achieved. It is intended to provide

In the present invention, each phase coil is wound in the order of the first phase, the second phase, and the third phase without cutting the coil in the middle. Further, at this time, the second phase is wound in a direction opposite to that of the first and third phases. Next, the method of connecting each phase coil after winding is the first method, in which the starting end of the winding is the outlet of the first phase, and the end of the winding of the second phase is connected to the winding end of the third phase. Cut between the beginnings and make 2 and 3 pieces respectively.
The winding end is connected between the winding end of the first phase and the winding start of the second phase to form a neutral point. The terminal end is the outlet of the third phase, and the end of the winding of the first phase and the start of the winding of the second phase are cut to become the outlet of the first and second phases, respectively, and the start end of the winding is It is connected between the winding end of the second phase and the winding start of the third phase to form a neutral point. The first method and the second method differ only in the winding direction of each phase coil, and similar three-phase Y-connected coils are formed.

In the above-mentioned winding and wiring steps, in order to enhance the effects of the present invention, the following stator end face insulating plates are used.

First, as a first end face insulating plate, a crossover wire is provided near the outer circumference of the stator on the outer diameter side of the stator core slot, and has two steps and a tapered portion connecting these steps. A guide wall will be erected. Now, among the two steps mentioned above, the one closer to the stator core is the lower step, and the other is the upper step.
In the coil winding process, the crossover wire that connects the same-phase coils of the first phase crosses along the lower stage, and the crossover wire that connects the same-phase coils of the second phase first runs along the lower stage, and then goes to the upper stage at the above-mentioned taper part on the way. After that, the crossover wires connecting the in-phase coils of the third phase are configured to cross along the upper stage.By configuring this way, the crossover wires of each phase This allows them to cross without crossing each other.

Next, as a second end face insulating plate, a crossover wire guide wall is erected at the same position as the first end face insulating plate, and a plurality of side walls protruding toward the outer diameter side are provided at a predetermined portion of the crossover wire guide wall. , and another predetermined portion is provided with one notch. In the coil winding process, the connecting wire portion between the phases that is to be cut later and becomes the exit portion is the above-mentioned 1llIIl! The connecting wire guide wall is configured to extend along the outer diameter side of the connecting wire guide wall while being isolated from the connecting wire guide wall. Further, in the coil winding process, a crossover wire portion between phases that will later become a neutral point is configured to cross through a notch in the crossover wire guide wall.

Normally, in order to facilitate the wiring work, an outlet and a neutral point, which require a soldering process, are provided on one end face in the axial direction of the stator, and a connecting wire between the in-phase coils is provided on the other end face. In that case, the first and second end face insulating plates are attached to each end face of the stator core depending on the respective use, but generally, from the necessity of saving mold costs, A practical structure is to manufacture an end insulating plate having both the structures of the first and second end insulating plates described above, and to use this by attaching it to both end faces of the stator core.

<Example> The present invention will be described in detail with reference to drawings showing examples. FIG. 1 is a configuration diagram of a stator coil of a three-phase, four-pole brushless motor showing an embodiment of the present invention. One stator coil is formed per tooth by directly winding the electric wire. In the coil winding process, winding starts from the winding start end 16, first, a predetermined number of turns are wound around one tooth to wind one coil 17a of the first phase 17, and then one coil 17a of the first phase 17 is wound. 23-1, the other coil 11b of the first phase 17 is wound around another toothed portion with the same number of turns and in the same direction as the coil 17a. Next, it moves to another tooth part via the connecting wire 21 between the phases, and similarly to the first phase 17, the coils 18a and 18b of the second phase 18, and the coil 1 of the third phase 19 are connected.
9a and +9b are respectively wound to reach the winding end 20.

Here, for coil 17a or 17b, coil +
Coils 8a and 18b have the same number of turns but in opposite winding directions, and coils 19a and 19b have the same number of turns and the same direction of winding.

Next, regarding the wiring method, in Fig. 1(a), the winding start end 16 is used as the outlet of the first phase 17, and the inter-phase transition 'm22 is cut to connect the second phase 18 and 3. Form the exit part of the th phase 19, and connect the winding end 20 to the connecting wire 21 between the phases.
By connecting it to the neutral point, a three-phase Y-connected coil can be formed. In addition, in FIG. 1(b), the winding end 20 is
The outlet of the second phase 19, and the crossover wire 2 between the phases.
1 is cut to form the outlet of the first phase 17 and second phase 18, and the winding start end 16 is connected to the crossover wire 22 between the phases to serve as a neutral point, a three-phase Y-connected coil is created. Can be formed. That is, 2
By winding the 3rd phase in the opposite direction to the 1st and 3rd phases, all the coils can be wound without cutting the coils of each phase midway.

FIG. 2 is a developed view of the stator coils shown in FIG. 1(a), and the arrows in the figure indicate the winding directions of the coils or the crossing directions of the crossover wires. By winding as shown in FIG. 2, the winding start end 16 becomes the outlet or neutral point of each phase,
End of volume 20, Somon no Watari I! 1i 21 and 22 at one end of the stator in the axial direction, and the transition between the same phase coils m 23
-1.23-2.23-3 are arranged at the other end, and as a result, all the parts that require connection processing in the subsequent process can be concentrated at one end of the stator. Furthermore, the overlap between the connecting wires 23-1, 23-2, and 23-3 between the in-phase coils can be set to two or less at all locations.

The crossover wires between the in-phase coils are made to cross over without crossing each other using the end face insulating plates of the stator, and this situation is shown in FIG. 3. In the figure, reference numeral 31 denotes an end face insulating plate used in the present invention, which is formed by resin molding into a predetermined shape to cover the axial end face of the stator core 1 and the inside of the slot.
8i is viewed from both end faces of the iron core 1. This end face insulating plate 31 has wall portions erected on the inner circumferential side and outer circumferential side of the stator for guiding the coil during coil winding, and the wall portion on the outer circumferential side has two
The stepped portions are provided to also serve as guides for crossover wires between coils of the same phase. This crossover wire guide wall 24 is erected in a substantially annular shape on the end face of the stator, and has a tapered portion that connects and communicates the lower stage and the upper stage in the vicinity of the coils 19b and 17a shown in the embodiment of FIG. I own one. Each crossover wire connecting the in-phase coils shown in the embodiment of FIG. 2 is pulled out from each coil to the back of the crossover wire guide wall, and the crossover wire 23-
1 becomes the crossing line 23a that crosses the lower level, and also crosses @ 23
-3 is a crossover wire 23b that crosses the upper stage. On the other hand, crossover line 23
-2 is an intrusion that comes out of the coil 18a and crosses the lower stage to the back of the coil 19b, passes through the tapered part 25 shown in FIG.
Cross the upper level until you enter. Each crossover wire can be taken in and out of the back of the crossover wire guide wall 24 by providing a groove extending downward in the axial direction from the upper end of the crossover wire guide wall 24. This can be easily done by moving in a direction perpendicular to the axis. At this time, by setting the depth of the groove on either the upper or lower surface of the crossover wire guide wall, the crossover wires are placed on the respective stages. Therefore, in the present invention, the connecting wires are distributed to the lower stage in the first half of the winding process and to the upper stage in the latter half of the winding process according to the winding order, so that the connecting wires do not cross each other.

Further, on the other end face of the stator where the outlet portions and neutral points of each phase are connected, the respective connections are made using end face insulating plates shown in FIGS. 5 and 6. In FIG. 5, 26-1, 26-2, 26-3,
26-4 is a side wall provided integrally with the crossover wire guide wall 24, and 27 is a lead wire holding portion integrally formed with the end face insulating plate 31. Winding start end 16 shown in the embodiment of FIG.
passes through the outside of the side wall 26-4 to the side walls 26-3 and 26-
4, and the connecting wire 22 between the phases is pulled out from the 111 part of the coil 18b to the back of the connecting wire guide wall 24, and then the outside of the side walls 26-2 and 26-1 is red and white. It is passed to the coil 19a. Lead wire +2 clamped to lead wire holder 27 by clamp piece 29
-+.

12-2 and 12-3, the core wire portion of the lead wire 12-1 is connected to the winding start end 16, and the core wire portions of the leads @ 12-2 and 12-3 are separated from each other via the g1 wall 26-1. They are positioned in substantially contact with the connecting wires 22, and then their respective contact portions are soldered. If the electric wire constituting the coil is made of an insulating film such as polyurethane that is melted into solder, the above-mentioned connection is very easy. After the above soldering, the connecting wires 22 are connected to the lead wires 12-2 and 12-
3. A predetermined length is cut in the middle of each connection part, and as a result, three phase outlet parts are completed. As shown in the diagram,
By forming the stepped portion 33 on the outside of the side wall, it becomes easy to position the lead wire and the electric wire.

On the other hand, Fig. 6 is a diagram explaining the connection of the neutral point, and 2 in the figure
Reference numeral 8 denotes a notch provided in the crossover guide wall 24. The interphase crossover wire 21 shown in the embodiment of FIG. 2 is drawn out from the winding end of the coil Rh to the back of the crossover wire guide wall 24, and then is crossed to the coil 18a via the notch 28. . Further, the end winding 120 is pulled out from the coil +9b to the back of the connecting wire guide wall 24, and then guided to the notch 28. Thereafter, in the wiring process, the winding end 20 is soldered to the phase transition @ 21 and the notch 28 to complete the neutral point. In this case as well, connection is very easy if the wire has an insulating film that can be melted into solder.

The end face insulating plate used on the lead wire side of the stator shown in FIGS. 5 and 6 and the end face insulating plate used on the opposite side shown in FIGS. 3 and 4 are formed of the same type. Therefore, it is formed having all the functions shown in FIGS. 3 to 6. It is desirable that the side walls 26-1 to 26-4 shown in FIG. 5 and the notch 28 shown in FIG. , wire connection work can be done without being hindered by the coils wound around the teeth. In addition, the lead wire holding portion 27 of the end face insulating plate used on the anti-Sunday side is cut off, and the clamp piece 2 used on the Sunrise line side is cut off.
It may be used as 9. Further, on the side opposite to the exit portion, the crossover wire between the in-phase coils that crosses the portion where the side walls 26-1 to 26-4 are provided is connected to a stepped portion 331. :By passing the upper crossover along the line, crossing of the crossover can be avoided.

The stator that has undergone the above-described wiring process is integrally fixed to the housing by resin molding. As a result,
The aforementioned connection points are covered with resin to maintain insulation, while each crossover wire is also fixed while maintaining its respective position.

<Effects of the Invention> In the manufacturing method of the present invention, there are only two terminals, the winding start end and the winding end, after winding the coil, so the loosening of the coil is reduced compared to the conventional coil having six terminals. This prevents the coil from coming off the teeth, making it easier to handle during production. In the wiring process, by providing a crossover wire between the phases, two lead wires can be directly connected at this part, and by using this part as a lead wire extraction part, wiring can be done simply and with good workability. becomes. In addition, by providing a crossover wire between phases, a neutral point can be formed by simply connecting two wires, and since appropriate tension is applied to the crossover wire, the connection point of the neutral point can be connected later. There is no deviation during the process. In other words, according to the present invention, wiring work is facilitated and motor assembly is simplified.

In addition, by concentrating the portions that require wiring work in the subsequent process on one end of the stator in the axial direction, and at the other end, connecting wires between coils of the same phase cross each other without intersecting wires of the other phase. The wiring work at all ends becomes easy, and a sufficient insulation distance between the connecting wires is ensured at the other end, thereby greatly improving the quality of the motor.

Furthermore, the side wall installed on the crossover wire guide wall of the end insulating board allows
Since the connection point of the lead wire can be isolated from the crossover wire guide wall, the connection work is facilitated, and the side wall interposed between the connection points described in 11i'l prevents the connection point from moving, so that the connection points can be separated from each other. Insulation is ensured. In addition, by connecting the neutral point in the notch provided in the crossover wire guide wall of the end face insulating plate, the soldering can be performed without damaging the crossover wire guide wall with a tool or a metal fitting. The work can be done easily.

Furthermore, the present invention can easily and reliably fix the wire connection points as described above, and the wire connection points can be prevented from shifting even if subjected to pressure etc. during resin molding of the stator in the subsequent process. On the other hand, the molded resin completes the insulation of the connection points. Therefore, the conventionally used printed wiring board is no longer necessary, the cost of the motor is reduced, and the motor can be made smaller.

[Brief explanation of drawings]

1 to 6 show embodiments of the present invention, and FIG.
) and (b) are configuration diagrams of the stator coil of a three-phase brushless motor showing different embodiments, Figure 2 is a developed view of the stator coil shown in Figure 1 (a), and Figure 3 is the stator coil. FIG. 4 is a front sectional view of the main part showing the side opposite to the exit part, FIG. 4 is a perspective view of the main part showing the tapered part of the crossover guide wall, and FIGS.
The figure is a perspective view of the main part explaining the function of the end face insulating plate on the outlet side of the stator, Figures 7 to 10 show the stator of a conventional three-phase brushless motor, and Figure 7 is a schematic explanation. figure,
Fig. 8 is a partially sectional plan view seen from the outlet side, Fig. 9 is a front view of the main part showing another embodiment of the wiring method, and Fig. 10 is the 7th
FIG. 3 is a developed view of the stator coil shown in the figure. 12-1.12-2.12-3--- Lead wire, 1
B---Start of one roll, 17------1st phase, 111
1---Second phase, one third phase, 20---
End of one roll, 21.22 --- Crossing wire between one phase, 23-1
．． 23-2.23-3---crossover wire between in-phase coils,
24---One wire guide wall, 25---Tapered part,
26-1.26-2.26-3.26-4---One side wall, 28---Complete portion, 31---One end surface insulating plate, 32
----- Coil. 2nd Leap Figure 10 9r4

Claims (4)

[Claims] (1) In a brushless motor in which Y-connected three-phase coils are wound around the teeth of a stator core, the first phase, second phase,
Winding the second phase and the third phase sequentially from the winding start end to the winding end, with the winding direction opposite to the first and third phases,
After winding each phase coil, the winding start end becomes the first phase outlet, and the winding end of the second phase and the winding start of the third phase are cut to form 2 and 3 windings, respectively. The winding end is connected between the winding end of the first phase and the winding start of the second phase to form a neutral point, or after the winding of each phase coil is wound. , the end of the winding is used as the outlet of the third phase, and the end of the winding of the first phase and the beginning of the winding of the second phase are cut to become the exits of the first and second phases, respectively. , the beginning of the volume is 2
A method for manufacturing a stator for a three-phase brushless motor, characterized in that the stator is connected between the winding end of the third phase and the winding start of the third phase to form a neutral point. (2) The outlet and neutral point of each phase coil are provided at one end of the stator in the axial direction, and the crossover wire connecting the coils of the same phase is provided at the other end without intersecting those of other phases. A method for manufacturing a stator for a three-phase brushless motor according to claim 1, characterized in that: (3) A stator end face insulating plate that is attached to both end faces of the stator core to electrically insulate the stator core and the coil,
A stator end face insulating plate characterized in that a crossover wire guide wall having two step sections and one tapered section connecting these steps is erected in the vicinity of the outer periphery. (4) A stator end face insulating plate that is attached to both end faces of the stator core to electrically insulate the stator core and the coil,
A crossover wire guide wall is erected near the outer periphery, a plurality of side walls protruding toward the outer diameter side are provided at a predetermined portion of the crossover wire guide wall, and a notch is provided at another predetermined portion. stator end face insulating plate.