JPH0870559A - Electric motor manufacturing method - Google Patents

Abstract

(57) [Abstract] [Object] The present invention configures a wiring board capable of wiring with a large current capacity even if the area is small, and manufactures a motor that connects a winding of a small-sized and high-output motor with the wiring board. The purpose is to get a way. [Structure] A conductive metal plate is punched with a press die 5 to form a wiring pattern 2, and after punching with the press die 5, the punched part is returned to the position before punching by pushback, and the insulating member 10 is attached to one of the wiring patterns 2. Then, the wiring board 1 is formed, the winding ends are connected to the wiring pattern 2, and the unnecessary portion 12 formed by punching the conductive metal plate is removed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an electric motor in which winding ends and the like are connected via a wiring board.

[0002]

2. Description of the Related Art In a method of manufacturing an electric motor in which a plurality of winding ends are connected by a wiring board such as a printed circuit board, since the winding ends are connected to the printed wiring of the printed circuit board, a current flowing through the winding flows through the printed wiring. It will be. For this reason, in a motor with a large output, it has been necessary to increase the cross-sectional area of the printed wiring to handle a large current. However, since the thickness of the printed wiring is usually about 35 μm, the width of the printed wiring must be increased in order to increase the cross-sectional area. Therefore, if the width of the printed wiring is increased, the current capacity is proportionally increased, but the area of the printed wiring board required for the printed wiring is increased, and the outer diameter of the printed wiring board is increased.

Generally, when a winding end of an electric motor is connected by using a printed wiring, if the printed circuit board is larger than the outer diameter of the electric motor, it cannot fit inside the frame of the electric motor, which is extremely inconvenient. Problems like this
When it is constructed so that only the winding ends are connected, it usually fits within the outer diameter of the motor. However, when other components such as Hall ICs are mounted on the printed circuit board at the same time, the printed circuit board is more than the outer diameter of the motor. Can be large. Therefore, when the width of the printed wiring becomes large, such a problem is likely to occur, and a method has often been adopted in which the printed board is double-sided to expand the utilization area.
However, when the double-sided wiring is used as described above, there is a possibility that one of the wirings may come into contact with the winding wire in close proximity, and it may be necessary to provide insulation between the winding wire and the printed circuit board.
However, when insulating between the printed circuit board and the winding, the winding ends are connected to the printed circuit board through an insulator,
It wasn't a very rational structure.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and constitutes a wiring board capable of wiring with a large current capacity even with a small area, and is a small-sized and high-output electric motor. An object of the present invention is to obtain a method for manufacturing an electric motor in which the windings of the above are connected by a wiring board.

[0005]

[Means for Solving the Problems] A conductive metal plate is punched out by a press die to form a wiring pattern, and after punching by this press die, the punched-out portion is returned to the position before punching by insulating the wiring pattern on one side. The problem is solved by mounting members to form a wiring board, connecting winding ends to this wiring pattern, and removing unnecessary portions formed by the punching of the conductive metal plate.

[0006]

Since the punched wiring pattern returns to the position before punching by the press-type pushback, the insulating member can be mounted in this state without breaking up. Since the wiring pattern is held by the insulating member when the insulating member is attached, unnecessary parts other than the punched wiring pattern can be removed without being separated, and wiring can be performed only by the insulating member and the wiring pattern. The substrate can be constructed. During this time, windings and parts can be connected as necessary, and the wiring pattern is made of a punched member of a conductive metal plate,
Compared with general printed wiring, the wall thickness is extremely large, a sufficient cross-sectional area can be secured, and the mechanical strength becomes large, which is convenient for mounting parts. Even when the current flowing through the winding becomes large, the cross-sectional area of the wiring pattern is large, and there is no danger of heat generation, and since it is not necessary to increase the width of the wiring pattern, the insulating member and the wiring pattern are integrated. Even if it is made, the outer diameter does not become large, and it can be installed in a small electric motor. For example, in order to increase the output, it is possible to manufacture an electric motor that is axially long and has a small outer diameter.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described based on an embodiment shown in the drawings. FIG. 1 is a plan view showing the shape of a wiring board used in a method for manufacturing an electric motor of the present invention. FIG. 2 is a vertical cross-sectional view of a main part showing a state where a conductive metal plate is punched out by a press die to form a wiring pattern. FIG. 3 is a vertical cross-sectional view of a main part showing a state in which a conductive metal plate is punched by a press die to form a wiring pattern. FIG. 4 is a vertical cross-sectional view of a main part showing a state in which a conductive metal plate is punched by a press die and a wiring pattern is manufactured by push-back of a press die. FIG. 5 is a vertical cross-sectional view of an essential part showing a state in which an unnecessary part of the wiring pattern is removed. FIG. 6 is an enlarged vertical cross-sectional view showing an essential part showing a state in which an insulating member is attached to one of the wiring patterns. FIG. 7 is a vertical sectional view of an electric motor manufactured according to the present invention.

In FIG. 1, the wiring board 1 has 0.5 to 2
The wiring pattern 2 is formed of a conductive metal plate having a thickness of about mm, and the wiring pattern 2 is formed by punching with a press die. The wiring pattern 2 has a plurality of through holes 3,
4 is formed, a winding end or a part (not shown) is connected to a part of the through holes 3, and an insulating member (not shown) is also attached to the part of the through holes 4. .

In FIG. 2, the manufacturing method of the wiring board 1 is as follows.
A conductive metal plate made of a copper plate forming a wiring board is inserted into the press die 5, punched, and then the portion punched by pushback is returned to the position before punching. The press die 5 is configured such that the punch 6 for punching moves up and down.
A die 7 is provided below the punch 6, and a pushback knock pin 8 is provided to return the conductive metal plate punched by the die 7 and the punch 6 to the position before punching. The knock pin 8 is configured to return by a spring 9, and the conductive metal plate punched by this return is returned to the position before punching. This knock pin 8 returns
As shown in this embodiment, in addition to the spring 9, the operation can be performed by hydraulic pressure or the like, and a general pushback type press die can be used.

In FIG. 3, in the press die 5, the punch 6 descends and the portion of the wiring pattern 2 of the conductive metal plate is diced into a die 7.
The knock pin 8 is pushed into the inside of the spring against the spring 9. The portion punched out by the punch 6 has a predetermined shape that becomes the wiring pattern 2.

Referring to FIG. 4, in the press 5 type, the knock pin 8 is returned by the spring 9, and the wiring pattern 2 punched by the punch 6 by the knock pin 8 is returned to the position before punching. The conductive metal plate is taken out from the press die 5 in such a state. The conductive metal plate may be taken out of the press die 5 sequentially in the direction perpendicular to the punching as in the progressive die, or in the manual feed progressive die.

In FIG. 5, the wiring board 1 has an insulating member 10 mounted on one side of the wiring pattern 2, and the insulating member 10 has through holes 4 formed in various places of the wiring pattern 2.
It is configured such that the projection portion 11 is fitted to and the tip portion of the projection portion 11 is plastically deformed and fixed. Then, with the insulating member 10 attached to the wiring pattern 2 and the wiring pattern 2 does not come apart, the wiring board 1
The unnecessary portion 12 other than the wiring pattern 2 is removed. At this time, various components 13 are attached to the wiring pattern 2, the insulating member 10 is configured to be mounted, and the insulating member 10 is preferably formed with the pocket 14 so as to accommodate these components. . Further, in such an insulating member 10, the protruding portion 11 is not fitted into the wiring pattern 2 to be mounted, but the insulating member 10 is melted in the state where the unnecessary portion 12 is provided and the through hole of the wiring pattern 2 is provided. The insulating member 10 can be formed by integrally curing the wiring pattern 4 and the wiring pattern 2. Alternatively, the insulating member 10 may be mounted on a molding die and injection-molded. In this case, when the insulating member 10 is injected and mounted on only one side of the wiring pattern 2, the injection resin is injected into the through hole 4 of the wiring pattern 2. Since it can be injected, the wiring pattern 2 and the insulating member 10 are integrated. Further, even by these methods, since the through hole is not formed in the unnecessary portion 12, the injected resin is not integrated, and the unnecessary portion 12 can be pulled and peeled later.

In FIG. 6, the wiring board 1 is an insulating member 1.
The protruding portion 11 of 0 is fitted in the through hole 4 of the wiring pattern 2, and the tip end portion is plastically deformed by heating or the like, and the insulating member 10 and the wiring pattern 2 are integrated. And
The lead wire 15 of the component 12 penetrates through the through hole 3 formed in the wiring pattern 2 and is connected to the wiring pattern 2 by the solder 16.

In FIG. 7, the electric motor is composed of a stator 17 and a rotor 18, and a frame 19 is provided to hold the stator 17 in order to integrate them, and the frame 19 is integrated with the frame 19. Bracket 2 to be
0 is provided so that both can rotate the rotor 18 inside the stator 17. The wiring board 1 is provided inside the frame 19, and the insulating member 10 is located on the stator 17 side.

In such a structure, in the method of manufacturing an electric motor, a conductive metal plate such as a copper plate is punched with the press die 5 to form the wiring pattern 2, the insulating member 10 is mounted, and then the unnecessary portion 12 of the conductive metal plate is removed. The wiring board 1 is formed by removing. Since the formed wiring pattern 2 is incorporated inside the electric motor, the winding end and the like (not shown) are connected together with the component 13 and housed inside the frame 19 of the electric motor to assemble the electric motor. According to such an assembly, even if the output of the motor is large and the operating current is increased, unlike the conventional printed wiring, if the thickness of the conductive metal plate is increased, the cross-sectional area of the conductive portion can be easily increased. It can be made large, and can withstand a large current sufficiently.

When such a wiring pattern 2 is punched out by the press die 5, a part of the wiring pattern 2 is projected in the punching direction. Therefore, if the wiring pattern 2 is formed in a projecting state when it is pressed back, three-dimensional wiring is possible, and the conventional printed wiring board is used. Unlike the wiring pattern 2, since the wiring pattern 2 has a certain thickness and a large mechanical strength, it can be used as a protrusion.
Such a protrusion can be used as a spigot for fitting a bracket, and when the wiring boards 1 are stacked and used, they are used for connection between adjacent wiring boards 1 and the like. Different from the printed wiring of the above, various configurations can be realized by utilizing a large mechanical strength. Also,
It is also possible to cut the protruding part and erect the pin,
In this case, the pins form terminals, and the wiring board 1
It is convenient as

[0017]

According to the present invention, there is provided a method of manufacturing an electric motor in which a wiring board capable of wiring with a large current capacity is constructed even if the area is small, and a winding wire of a small and large output electric motor is connected by the wiring board. The effect is extremely large.

[Brief description of drawings]

FIG. 1 is a plan view showing a shape of a wiring board used in a method for manufacturing an electric motor of the present invention.

FIG. 2 is a vertical cross-sectional view of a main part showing a state in which a conductive metal plate is punched with a press die to form a wiring pattern.

FIG. 3 is a vertical cross-sectional view of a main part showing a state where a conductive metal plate is punched out by a press die to form a wiring pattern.

FIG. 4 is a vertical cross-sectional view of a main part showing a state in which a conductive metal plate is punched with a press die and a wiring pattern is manufactured by pushback of a press.

FIG. 5 is a vertical cross-sectional view of an essential part showing a state in which an unnecessary part of a wiring pattern is removed.

FIG. 6 is an enlarged vertical sectional view showing an essential part showing a state where an insulating member is attached to one of the wiring patterns.

FIG. 7 is a vertical cross-sectional view of an electric motor manufactured according to the present invention.

[Explanation of symbols]

 1 ………… Wiring board 2 ………… Wiring pattern 3 ……… Through hole 4 ……… Through hole 5 ……… Press type 6 ……… Punch 7 ……… Die 8 ……… Knock pin 9 ……… Spring 10 ... Insulating member 11 ... Projection 12 ... Unnecessary portion 13 ... Parts

Claims (1)

[Claims] 1. A method for manufacturing an electric motor in which winding ends and the like are connected by a wiring board forming a predetermined wiring pattern, a conductive metal plate is punched out by a press die to form a wiring pattern, and the die is punched by the press die and then pushed. The punched part is returned to the position before punching by the back, an insulating member is attached to one of the wiring patterns to form a wiring board, the winding ends are connected to this wiring pattern, and the conductive metal plate is formed by the punching. A method for manufacturing an electric motor, which comprises removing unnecessary parts.