WO2017134722A1

WO2017134722A1 - Rotary motor and method for manufacturing rotary motor

Info

Publication number: WO2017134722A1
Application number: PCT/JP2016/052878
Authority: WO
Inventors: 幸恵山川; 宏志山中; 一輝藤本; 遼並河; 孝則清水
Original assignee: 三菱電機株式会社
Priority date: 2016-02-01
Filing date: 2016-02-01
Publication date: 2017-08-10

Abstract

The rotary motor has at least two first protruding pieces and second protruding pieces that protrude upward from a top section positioned on the outer circumferential side of securing pieces for insulators, the first protruding pieces being formed from at least two protrusions that protrude above and below the outer circumferential surfaces of the securing pieces of the first protruding pieces, and having a coil path section in which the end wires of a coil are fed between the protrusions and contained thereby, and the second protruding pieces being formed from protrusions that protrude, from the outer circumferential surface of the securing pieces of the second protruding pieces, to a lesser extent than the coil path section, and having a coil supporting section that locks the end wires of the coil against the coil path section by pressing the end wires of the coil onto the bottom surfaces of the protrusions. Neutral points take the shape of twisted sections formed by intertwining the bare aluminum end wires of the coil, the twisted sections being joined by solder.

Description

Rotating electric machine and method of manufacturing rotating electric machine

The present invention relates to a rotating electrical machine integrally molded with a thermosetting resin, and a method for manufacturing the rotating electrical machine.

The drive unit of a conventional rotating electric machine is composed of an annular stator and a rotor that is rotatably held on the inner peripheral side of the stator. The stator is formed of a plurality of stator cores that are magnetic bodies, and an insulator that is an insulator is fitted into the stator core. A coil through which a current flows is wound around the insulator, a terminal is attached to a terminal engagement hole of the insulator, and the terminal and the coil terminal wire are joined by soldering or the like. These joints are classified into a lead wire side joint where one coil terminal wire is joined and power is supplied from the outside, and a neutral point where a plurality of coil terminal wires are joined.

Such a neutral point of the rotating electrical machine is joined by soldering or the like with a coil terminal wire wound around the upper portion of the terminal as described in Patent Document 1, for example.

JP-A-5-146106

In recent years, aluminum wire has come to be used as a stator coil for rotating electrical machines due to the rising price of copper wire. However, it is generally said that it is difficult for an operator to solder the aluminum wire and the terminal with a soldering iron or the like. This is performed in a state in which the coating of the coil terminal wire is removed, but aluminum forms a strong oxide film on the surface at the moment when it is exposed to the outside air, and the wettability of the solder is significantly reduced. Therefore, in order to remove the oxide film, it is necessary to apply solder to the base material and solder it. However, while heating the flux to a certain temperature or more and activating it, the base material is heated and further solder is supplied. Therefore, compared with the soldering of the copper wire which does not use a flux, it becomes very difficult. From the above, in soldering aluminum wires, it is strongly desired to introduce Dip soldering by a Dip automatic apparatus that is excellent in quality and work time.

Here, in Patent Document 1, soldering is performed in a state where a coil terminal wire is wound around a terminal. However, since a plurality of coil terminal wires are wound around a neutral point, a joint portion swells. For this reason, when the stator is installed in the Dip automatic device, there is a high possibility that the coil terminal wire is disconnected from the terminal by hitting a neutral point on the automatic device. This has a higher resistivity than copper and is more likely to occur with aluminum wires that are thicker than copper wires. Moreover, although not described in the above-mentioned Patent Document 1, for example, the same applies to the case where a coil terminal wire is sandwiched between terminals.

Therefore, if the coil terminal wires are fixed to each other by directly twisting the coil terminal wires without using a terminal, the neutral point is struck against the automatic device when the stator is installed in the Dip automatic device. It can be said that the possibility of the coil terminal wire coming off from the cable is further reduced.

However, when a neutral point is formed by twisting a plurality of coil terminal wires, the workability is poor because the coil terminal wires are not fixed, as described in Patent Document 1, and at the time of molding resin molding The neutral point and the coil terminal wire may move and be exposed on the resin surface.

The present invention has been made to solve the above-described problem, and even when a plurality of coil terminal wires are directly twisted to form a neutral point without using a terminal or the like fixed to an insulator. An object of the present invention is to provide a rotating electrical machine in which neutral points and coil terminal wires are not exposed from the resin surface during molding resin molding, and a method of manufacturing the rotating electrical machine.

A rotating electrical machine according to the present invention includes a molded annular stator and a rotor that is rotatably held on the inner peripheral side of the stator, and the stator includes a plurality of stator cores and a stator. An insulator fitted with an iron core and formed of an insulating material, an aluminum wire coil wound around the insulator, and a bare aluminum wire exposed by peeling of a coating of at least two coil end wires of the coil are joined together. The insulator has a neutral point to be formed, and the insulator has at least two first protrusions and second protrusions protruding upward from an upper part located on the outer peripheral side of the stator, and the first protrusions are A surface of the outer periphery of the stator of the first projecting piece, which is formed by at least two protrusions projecting above and below the surface, and has a coil path portion that encloses the coil terminal wire between the protrusions. The second protruding piece is fixed to the second protruding piece. It is a surface on the outer peripheral side of the child, and is formed by a protrusion that protrudes to a position lower than the coil path portion of the surface, and the coil terminal wire is placed on the lower surface of the protrusion so that the coil terminal wire is locked with the coil path portion. The neutral point has a shape of a twisted portion in which bare aluminum wires of coil terminal wires are entangled with each other, and the twisted portion is joined with solder.

According to the present invention, the insulator fitted to the stator iron core has at least two first protrusions and second protrusions protruding upward from an upper portion located on the outer peripheral side of the stator of the insulator, The one protrusion piece is a surface on the outer peripheral side of the stator of the first protrusion piece, and is formed by protrusions that protrude at least two above and below the surface, and a coil that holds the coil terminal wire between the protrusions. The second protrusion piece is a surface on the outer peripheral side of the stator of the second protrusion piece, and is formed by a protrusion protruding at a position lower than the coil path portion on the surface. It has a coil support part which puts a coil terminal wire into a locked state with the coil path | route part by contacting with the lower surface of a processus | protrusion. The neutral point is a shape of a twisted portion in which bare aluminum wires of coil terminal wires are entangled with each other, and the twisted portion is joined with solder.
This eliminates the possibility that the coil terminal wire is detached from the insulator, so that it is possible to twist with the root of the neutral point fixed at the time of twisting work, and the coil terminal wire and neutral point are formed during molding resin molding. Since it does not move due to pressure, productivity and quality can be improved. Further, since the neutral points are joined directly by solder without using a terminal, the quality of the neutral point of the stator is improved, and the cost can be reduced by eliminating the neutral point.

It is sectional drawing which shows schematic structure of the rotary electric machine in embodiment of this invention. It is sectional drawing which shows the state which attached the propeller fan to the rotary electric machine of FIG. FIG. 2 is a perspective view showing a state before neutral point winding of the stator of the rotating electric machine of FIG. 1. It is a perspective view which shows the stator core in embodiment of this invention. It is a top view of 3 directions which shows the insulator in embodiment of this invention. It is explanatory drawing of the coil terminal wire and insulator on the insulator which expand | deployed and shows the stator core of the rotary electric machine in embodiment of this invention. It is a perspective view which shows the principal part of the neutral point after soldering in embodiment of this invention. It is a perspective view which shows the principal part of the neutral point before mold in embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below.

FIG. 1 is a sectional view showing a schematic configuration of a rotating electrical machine according to an embodiment of the present invention, and FIG. 2 is a sectional view showing a state where a propeller fan is attached to the rotating electrical machine of FIG.

Rotating electrical machine 1 in the present embodiment is a brushless DC motor for driving propeller fan 100 as shown in FIG. 2, for example, and is mounted on an outdoor unit of an air conditioner. As shown in FIG. 1, the rotating electrical machine 1 is rotatably held on a cylindrical motor housing 4, an annular stator 2 incorporated in the motor housing 4, and an inner peripheral side of the stator 2. The rotor 3 is provided.

The motor housing 4 includes a casing 5 in which the stator 2 is integrally molded with a thermosetting resin, and a bracket cover 8 including an insulating bracket 6 and a sheet metal bracket 7 that cover the opening side of the casing 5. Yes.

The rotor 3 holds a plurality of permanent magnets 10 disposed on the outer peripheral side of the disk-shaped rotating body 9 so as to face the inner periphery of the stator 2. A shaft 11 penetrating in the axial direction of the rotating body 9 is press-fitted and fixed at the center of the rotating body 9. A pair of bearings 12 is attached to the shaft 11. One bearing 12 is fixed to the bearing insertion portion 5 a of the casing 5, and the other bearing 12 is fixed to the bearing insertion portion 6 a of the insulating bracket 6. The bearing insertion portion 5 a and the bearing insertion portion 6 a are located on the central axis of the annular stator 2.

With the above configuration, the rotor 3 is arranged on the inner peripheral side of the stator 2 and rotates on the same axis as the annular stator 2. A printed circuit board 13 on which a Hall element for detecting the magnetic pole position of the rotor 3 is mounted is disposed between the end face of the rotor 3 and the insulating bracket 6. The printed circuit board 13 is fixed to a printed circuit board holder 14 fixed to the motor housing 4 by welding or the like.

Next, the structure of the stator 2 will be described with reference to FIG.
FIG. 3 is a perspective view showing a state before neutral point winding of the stator of the rotating electric machine of FIG.
The stator 2 is formed by combining a plurality of stator cores 15 made of a magnetic material, for example, twelve stator cores 15 in an annular shape. An insulator 16 made of an insulating material is attached to each stator core 15 at both ends in the axial direction of the stator 2. Furthermore, an aluminum wire coil 17 is wound around the plurality of insulators 16.

Three specific terminals 18 for supplying three-phase power to the coil 17 are attached to three specific insulators 16 among the plurality of insulators 16. Each terminal 18 is joined with a coil terminal wire of a coil 17 wound around an insulator 16 to which the terminal 18 is attached. This coil terminal wire is a bare aluminum wire on the winding end side of the coil 17 wound around the insulator 16.

The

coil terminal wires

171, 172, and 173 on the winding start side of the coils 17 of the respective phases have exposed

bare aluminum wires

171 a, 172 a, and 173 a from which the coating has been peeled, and these three bare aluminum wires 171 a are exposed. , 172a and 173a are joined by soldering to form a neutral point. In the

coil terminal wires

171, 172, and 173 of the respective phases, portions at the beginning of peeling that are boundaries between the coating and the peeling portion are referred to as peeling start points 171 b, 172 b, and 173 b.

Next, the stator core 15 and the insulator 16 which are main components of the stator 2 will be described with reference to FIGS. 4 and 5.
FIG. 4 is a perspective view showing a stator core in the embodiment of the present invention, and FIG. 5 is a plan view in three directions showing an insulator in the embodiment of the present invention.
A pair of insulators 16 having different shapes on the upper and lower sides are fitted to the upper and lower end portions of the stator core 15, but only the upper insulator 16 related to the present invention will be described here.

As shown in FIG. 4, the stator core 15 includes a back yoke portion 151 located on the outer peripheral side of the stator 2, and a teeth portion 152 formed to protrude from the back yoke portion 151 in the axial direction of the stator 2. It is composed of Further, the tooth portion 152 is provided so as to protrude from the center portion of the back yoke portion 151, and is provided with a teeth base portion 152a around which the coil 17 is wound via the insulator 16, and the tooth base portion 152a facing the back yoke portion 151. The teeth tip 152b is a space partition for accommodating the coil 17.

As shown in FIG. 5, the insulator 16 has a groove portion 161 a formed by opening the outer peripheral side and the lower side of the stator 2, and a central insulating portion 161 that fits with the teeth base portion 152 a of the stator core 15. An arc-shaped inner peripheral insulating portion 162 that is provided at a position on the inner peripheral side of the stator 2 of the central insulating portion 161 and into which the teeth tip portion 152b of the stator core 15 is fitted from below, and the central insulating portion 161 An outer peripheral insulating portion 164 formed in the outer peripheral side of the stator 2 and extending in the opposite direction from the central insulating portion 161 and contacting the inner peripheral surface of the back yoke portion 151 of the stator core 15; A projection piece 163 provided on the top, for example, three first projection pieces 163b, a second projection piece 163c, and a third projection piece 163a are provided.

The insulator 16 having such a shape is fitted from above the stator core 15, and an insulator (not shown) having a shape different from that of the insulator 16 is fitted from below the stator core 15. Thereafter, the coil 17 is wound on the central insulating portion 161 of the insulator 16. When the coil 17 is wound on the central insulating portion 161, the coil 17 is housed between the inner peripheral insulating portion 162, the outer peripheral insulating portion 164, and the protruding piece 163 of the insulator 16, as shown in FIG. It becomes a shape. By this insulator 16, the stator core 15 and the coil 17 are insulated.

In the insulator 16, the above-mentioned protruding pieces 163 are arranged, for example, as the third protruding piece 163a on the left side, the first protruding piece 163b on the center, and the second protruding piece 163c on the right side when the stator 2 is viewed from the outer periphery. The central first projection piece 163b is provided with a coil path portion 163de formed of a projection protruding outward on the outer peripheral surface of the stator 2. The coil path portion 163de is formed of an upper protrusion 163d and a lower protrusion 163e that are arranged with a space in the vertical direction. The distance between the upper protrusion 163d and the lower protrusion 163e is, for example, 1.3 to 1.5 times the wire diameter of the coil 17. The right second protrusion piece 163c is provided with a coil support portion 163f formed of a protrusion protruding outward on the outer peripheral surface of the stator 2. The coil support portion 163f is installed at a position lower than the lower protrusion 163e of the coil path portion 163de.

As described above, since the insulator 16 has a very simple insulator 16 shape in which at least three of the upper protrusion 163d and the lower protrusion 163e serving as the coil terminal line path and the protrusion-shaped coil support portion 163f need only be provided. The amount of resin and the amount of mold resin are not increased.

In addition, although each of the upper protrusion 163d and the lower protrusion 163e forming the coil path portion 163de is one, it is not limited to this. For example, the upper protrusion 163d may be one and the lower protrusion 163e may be two, and conversely, the upper protrusion 163d may be two and the lower protrusion 163e may be one.

Next, a method for joining neutral points formed by bundling the

coil terminal wires

171, 172, and 173 of each phase will be described with reference to FIGS. 6, 7, and 8.
FIG. 6 is an explanatory view of the coil terminal wires and neutral points on the insulator showing the stator core of the rotating electrical machine according to the embodiment of the present invention, and FIG. 7 is a diagram after the soldering in the embodiment of the present invention. The perspective view which shows the principal part of a sex point, FIG. 8: is a perspective view which shows the principal part of the neutral point before mold in embodiment of this invention.

(1) As shown in FIG. 6, the coil terminal wire 171 located on the left side of the central coil terminal wire 172 is inserted between the upper protrusion 163d and the lower protrusion 163e provided on the first protrusion piece 163b. The first projection piece 163b is placed on the outer peripheral side surface, and the second projection piece 163c is put on the outer peripheral side surface of the second projection piece 163c in a state where it is in contact with the lower surface of the coil support portion 163f. This is repeated for each insulator 16. In this case, the coil terminal wire 171 is locked by the coil support portion 163f positioned below the lower protrusion 163e and the lower protrusion 163e.
(2) On the other hand, the coil terminal wire 173 positioned on the right side of the coil terminal wire 172 is placed on the side surface on the outer peripheral side of the second projecting piece 163c in a state where the coil terminal wire 173 is applied to the lower surface of the coil support portion 163f of the second projecting piece 163c. And inserted between the upper protrusion 163d and the lower protrusion 163e provided on the first protrusion piece 163b, and is wound around the outer peripheral side surface of the first protrusion piece 163b. This is repeated for each insulator 16. Also in this case, the coil terminal wire 173 is locked by the coil support portion 163f positioned below the lower protrusion 163e and the lower protrusion 163e.
(3) Then, the coil terminal wire 171 is hooked on the coil support portion 163f closest to the coil terminal wire 172, and the coil terminal wire 173 is hooked on the upper protrusion 163d closest to the coil terminal wire 172. Bent in the axial direction.
(4) The central coil terminal wire 172 is extended in the axial direction as it is, and the two

coil terminal wires

171 and 173 are bundled together with the central coil terminal wire 172.

(5) Then, the three

coil terminal wires

171, 172, 173 are entangled in one direction to form a twist neutral point 174.
(6) Further, unnecessary lines that are not required during solder dip are cut. Here, the neutral point 174 is from the twist start point 174a of the

coil terminal wires

171, 172, 173 to the twist end point 174b which is the coil end, and the peeling start points 171b, 172b, 173b are the twist start point 174a and the twist end point. Between 174b.

As described above, before the

coil terminal wires

171 and 173 are twisted, the

coil terminal wires

171 and 173 can be supported by the coil path portion 163ed and the coil support portion 163f on the insulator 16, so that the coil terminal wires can be supported. The workability of twisting 171, 172, and 173 is improved.

In addition, since the

coil terminal wires

171 and 173 are entangled alternately with the lower protrusions 163e and the coil support portions 163f of the coil path portion 163ed, the possibility that the

coil terminal wires

171 and 173 are detached from the insulator during molding is smaller. Thus, the possibility that a part of the

coil terminal wires

171 and 173 are exposed from the surface of the mold is further reduced.

Further, since the distance between the upper protrusion 163d and the lower protrusion 163e of the coil path portion 163ed is 1.3 to 1.5 times the wire diameter of the

coil terminal wires

171, 172, 173, the insulator of the

coil terminal wires

171, 173 is used. Wiring by turning around 16 is easy and workability is improved.

(7) After the cut of the neutral point 174, as shown in FIG. 7, the automatic dip is soldered from the twist end point 174b of the neutral point 174 to the soldering base 174c (shaded portion). In this case, since the

coil terminal wires

171, 172, 173 are twisted and fixed to each other, there is a possibility that the neutral point 174 can be solved even if the neutral point 174 hits the device when installed in the device. Very low.
Also, by directly joining the

bare aluminum wires

171a, 172a, 173a of the

coil terminal wires

171, 172, 173, the possibility of corrosion due to the potential difference between different metals such as aluminum wires and copper terminals can be reduced, and the quality is improved. Further, it is possible to realize cost reduction by eliminating the neutral point 174 terminal.
Separation start points 171b, 172b, 173b exist between the torsion start point 174a and the torsion end point 174b of the

coil terminal wires

171, 172, 173, and further, the separation start points 171b, 172b, 173b and the torsion end point 174b exist. The above-mentioned soldering base 174c exists between the two. That is, the

bare aluminum wires

171a, 172a, and 173a of the

coil terminal wires

171, 172, and 173 that are not soldered exist between the soldering root 174c and the twist start point 174a.

As a result, even if water has soaked into the mold resin and the solder applied to the neutral point has been corroded and melted, the soldering base 174c and the peeling start points 171b, 172b, and 173b are originally not connected with the solder. Therefore, even if the solder corrodes, current flows and the function of the motor is not affected.

(8) The neutral point 174 after soldering is located between the protruding piece 163 of the insulator 16 and the outer periphery of the stator 2 with respect to the circumferential direction of the stator 2 as shown in FIG. Bending with respect to the axial direction of the stator 2 so that the twist end point 174b (terminal portion) of the neutral point 174 is located above the central insulating portion 161 of the insulator 16, and molding is performed with a thermosetting resin. Is done.

1 rotating electric machine, 2 stator, 3 rotor, 4 motor housing, 5 casing, 5a bearing insertion part, 6 insulation bracket, 6a bearing insertion part, 7 sheet metal bracket, 8 bracket cover, 9 rotating body, 10 permanent magnet, 11 Shaft, 12 bearing, 13 printed circuit board, 14 printed circuit board holder, 15 stator core, 16 insulator, 17 aluminum wire coil, 18 terminal, 100 propeller fan, 151 back yoke, 152 teeth, 152a teeth base, 152b Teeth tip portion, 161 central insulating portion, 161a groove portion, 162 inner peripheral insulating portion, 163 protruding piece, 163a third protruding piece, 163b first protruding piece, 163c second protruding piece, 163d upper protruding portion, 163e lower protruding portion, 163de coil Sutra Part, 163f coil support part, 164 outer periphery insulation part, 171, 172, 173 coil end wire, 171a, 172a, 173a bare aluminum wire, 171b, 172b, 173b peeling start point, 174 neutral point, 174a twist start point, 174b End of twisting, 174c Soldering root.

Claims

A molded annular stator,
A rotor rotatably held on the inner peripheral side of the stator,
The stator is
A plurality of stator cores,
An insulator fitted to the stator core and formed of an insulating material;
A coil of aluminum wire wound around the insulator;
A neutral point formed by joining bare aluminum wires exposed by peeling of a coating of at least two coil terminal wires of the coil;
The insulator is
Having at least two first protrusions and second protrusions protruding upward from an upper part located on the outer peripheral side of the stator,
The first projecting piece is
A coil path portion which is a surface on the outer peripheral side of the stator of the first projecting piece and is formed by at least two projections projecting above and below the surface, and the coil terminal wire is held between the projections. Have
The second protruding piece is
It is a surface on the outer peripheral side of the stator of the second protrusion piece, and is formed by a protrusion that protrudes to a position lower than the coil path portion of the surface, and the coil terminal wire is applied to the lower surface of the protrusion so that the coil A coil support portion that locks the coil terminal wire with the path portion;
The neutral point is a shape of a twisted portion in which bare aluminum wires of the coil terminal wires are entangled with each other, and the twisted portion is joined by solder.
The neutral point is soldered at the end of the torsion part, and the peeling start which is the boundary between the coil terminal wire and the bare aluminum wire between the root of the torsion part and the root of the soldering part The rotating electrical machine according to claim 1, wherein a point exists.
The rotating electrical machine according to claim 1 or 2, wherein the upper and lower intervals of the coil path portion are 1.3 to 1.5 times the wire diameter of the coil terminal wire.
The neutral point is located between the first and second protrusion pieces of the insulator and an outer periphery of the stator, and a terminal portion of the neutral point is located above the insulator. Item 4. The rotating electrical machine according to any one of Items 1 to 3.
At least two or more coil terminal wires of a coil wound around a stator core via an insulator are wound on a coil path provided in a first projecting piece of the insulator for each insulator, and the insulator Hooking on the lower surface of the coil support portion provided on the second projecting piece of the second projection piece, the step of turning in the circumferential direction of the stator,
Entangled and twisted the coil terminal wire spanned between the coil path portion and the coil support portion on the insulator, and entangled the bare aluminum wire of the coil terminal wire to form a torsion neutral point;
And a step of soldering an end of a neutral point formed by twisting the bare aluminum wire.