WO2012127603A1 - Procédé de fabrication pour une bobine cassette, procédé de fabrication pour un stator divisé, et procédé de fabrication pour un stator - Google Patents

Procédé de fabrication pour une bobine cassette, procédé de fabrication pour un stator divisé, et procédé de fabrication pour un stator Download PDF

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Publication number
WO2012127603A1
WO2012127603A1 PCT/JP2011/056758 JP2011056758W WO2012127603A1 WO 2012127603 A1 WO2012127603 A1 WO 2012127603A1 JP 2011056758 W JP2011056758 W JP 2011056758W WO 2012127603 A1 WO2012127603 A1 WO 2012127603A1
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WO
WIPO (PCT)
Prior art keywords
coil
stator
resin
manufacturing
cassette
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2011/056758
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English (en)
Japanese (ja)
Inventor
上野　泰弘
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
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Toyota Motor Corp
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Filing date
Publication date
Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Priority to JP2013505678A priority Critical patent/JP5590219B2/ja
Priority to PCT/JP2011/056758 priority patent/WO2012127603A1/fr
Publication of WO2012127603A1 publication Critical patent/WO2012127603A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • H02K15/043—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
    • H02K15/0431—Concentrated windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores

Definitions

  • the present invention relates to a method of manufacturing a cassette coil formed by resin-molding a coil made of a flat wire, a divided stator provided with the cassette coil, a method of manufacturing a divided stator formed by resin-molding a coil formed of a flat wire, and the divided stator. It is related with the manufacturing method of the stator provided with two or more.
  • Patent Documents 1 and 2 disclose the structures of these cassette coils, split stators, and stators.
  • FIG. 20 schematically shows a part of the stator 71 in a plan view.
  • FIG. 21 schematically shows a part of the stator 71 as viewed in the direction of arrow A in FIG. That is, as shown in FIGS. 20 and 21, when the stator 71 is formed by assembling a plurality of annular stators 74 in which the cassette coil 72 is assembled to the divided core 73, the resin is filled between the adjacent cassette coils 72. When the defective portion 75 is adjacent, the insulation resistance between the coils constituting the adjacent cassette coil 72 becomes low.
  • a first aspect of the present invention is a method of manufacturing a cassette coil obtained by resin-molding a coil made of a rectangular wire, and the coil is fitted into a cavity of a mold.
  • the purpose is to resin-mold the coil by filling the cavity with resin while holding one end of the coil in the axial direction opposite to the axial direction and toward the inner center of the coil.
  • the coil is reliably pressed in the inner direction.
  • the position where the side surface of the coil is pressed is asymmetrical in a plan view of the coil.
  • a cassette coil manufactured by any one of the manufacturing methods of the above configuration (1) to the above configuration (3) as a yoke portion.
  • the purpose is to manufacture a split stator by assembling to a tooth portion of a split core including a tooth portion.
  • a single stator by assembling a plurality of split stators manufactured by the manufacturing method having the above configuration (4) or (5).
  • the purpose is to manufacture.
  • (A)-(E) are perspective views showing a series of steps according to the stator manufacturing method according to the embodiment. Sectional drawing which shows the state which concerns on the embodiment and has set the insulator and the coil in the cavity of the metal mold
  • FIG. 8 is a cross-sectional view schematically showing a state where a pin is moved from the state of FIG. 7 according to the embodiment; Sectional drawing which expands and schematically shows the relationship between each pin and the rectangular wire of the upper part of a coil concerning the embodiment.
  • FIG. 9 is a cross-sectional view schematically showing a state in which the cavity is filled with resin from the state of FIG. 8 according to the same embodiment.
  • FIG. 4 is a plan view schematically showing a part of the stator according to the embodiment.
  • FIG. 12 is an arrow A view of FIG. 11 schematically showing a part of the stator according to the embodiment.
  • the perspective view which concerns on 2nd Embodiment and shows roughly the main structure of the insulator which set the coil, and a metal mold
  • FIG. 4 is a plan view schematically showing a part of the stator according to the embodiment.
  • the arrow A view of FIG. 15 which shows a part of stator according to the embodiment.
  • (A) to (E) are perspective views showing a series of steps related to a stator manufacturing method according to the third embodiment.
  • FIG. 6 is a cross-sectional view schematically showing a state in which the cavity is filled with a resin according to the embodiment. Sectional drawing which concerns on a prior art example and shows the process of resin-molding a coil. The top view which concerns on a prior art example and shows a part of stator schematically.
  • the arrow A view of FIG. 18 which shows a part of stator according to a prior art example schematically.
  • FIG. 1 is a plan view of the stator 1 according to this embodiment, with a part (cassette coil portion) cut away.
  • the stator 1 is a component of the motor, and the motor is configured by assembling the rotor inside and covering the outside with a housing.
  • the stator 1 is manufactured by assembling a plurality of divided stators 2 in an annular shape.
  • FIG. 2 is a perspective view showing one of the divided stators 2 constituting the stator 1.
  • the split stator 2 includes a split core 11 and a cassette coil 21.
  • the split core 11 includes a yoke part 11a and a tooth part 11b.
  • the split stator 2 is manufactured by assembling the cassette coil 21 to the tooth portion 11 b of the split core 11.
  • FIG. 3 is a perspective view showing the cassette coil 21 constituting the split stator 2.
  • the cassette coil 21 has a substantially trapezoidal quadrangular pyramid shape, and has a long hole portion 22 in plan view corresponding to the tooth portion 11b of the split core 11 at the center.
  • the cassette coil 21 is configured by a mold resin 23 and an insulator 24 in appearance.
  • the inner wall portion of the hole 22 and the bottom wall portion of the cassette coil 21 are each covered with an insulator 24.
  • FIG. 4 is a perspective view showing the insulator 24 and the coil 25 set on the insulator 24 before being resin-molded.
  • the coil 25 is formed by winding a rectangular wire 25a in two layers, and includes an inner inner layer coil 25A and an outer outer layer coil 25B. Both end portions of the flat wire 25 a protrude outward at one end portion of the coil 25 to constitute a pair of terminals 26.
  • FIG. 5 shows the insulator 24 in a perspective view.
  • the insulator 24 includes a rectangular frame-shaped bottom portion 24a and a long cylindrical portion 24b that rises upward from the bottom portion 24a.
  • the cylindrical portion 24b has a substantially square cylindrical shape, and is formed to rise upward from the inner edge of a long hole (not shown) formed in the center of the bottom portion 24a.
  • the insulator 24 is formed of an insulating material in order to ensure its function.
  • a set state shown in FIG. 4 is obtained by assembling the coil 25 to the cylindrical portion 24b of the insulator 24.
  • FIGS. 6A to 6E are perspective views showing a series of processes related to the manufacture of the stator 1 in this embodiment.
  • each of the insulator 24, the coil 25, and the split core 11 described above is manufactured in advance.
  • an insulator 24 is prepared, and subsequently, as shown in FIG. 6 (B), the coil 25 is set on the cylindrical portion 24b of the insulator 24.
  • the cassette coil 21 is manufactured by molding the periphery of the coil 25 shown in FIG. 6B with resin. This molding will be described later in detail.
  • the divided stator 2 is manufactured by setting the cassette coil 21 shown in FIG. 6D.
  • the stator 1 is manufactured by assembling a plurality of divided stators 2 in an annular shape.
  • FIG. 7 is a schematic sectional view showing a state where the insulator 24 and the coil 25 are set in the cavity 32 of the mold 31.
  • FIG. 8 is a schematic sectional view showing a state in which the plurality of pins 33 are moved from the state shown in FIG.
  • the mold 33 includes an upper mold 34, a middle mold 35 and a lower mold 36.
  • the upper die 34 is provided with a plurality of pins 33 for pressing the coil 25 so as to be movable up and down.
  • the plurality of pins 33 are arranged symmetrically in a plan view of the coil 25.
  • each pin 33 is moved downward, and each pin 33 moves one end of the coil 25 in the axial direction (the upper portion of the coil 25 in FIG. 8) to the opposite side (in FIG. 8). Press toward the inner side of the coil 25 and the lower side of the coil 25.
  • FIG. 9 is an enlarged schematic view of the relationship between each pin 33 and the rectangular wire 25a at the top of the coil 25. As shown in FIG. 9, a protrusion 33 a having a triangular shape is provided outside the lower end of the pin 33.
  • the pin 33a moves downward, the oblique side 33aa of the projection 33a hits the edge of the flat wire 25a, and the flat wire 25a is pushed in the inner direction of the coil 25 (the direction of the arrow X). That is, in this embodiment, at the time of resin molding, the rectangular wire 25a is simply pushed in the lower direction (by pressing the flat wire 25a on the upper side of the outer coil 25B from the product pressure direction of the coil 25 with the plurality of pins 33. It is configured to push in the direction of the arrow Y) and the inner center direction (the direction of the arrow X).
  • FIG. 10 is a schematic sectional view showing a state where the resin 41 is filled into the cavity 32 from the state shown in FIG.
  • the resin 41 filled in the cavity 32 of the mold 31 does not enter between the inner layer coil 25A and the outer layer coil 25B.
  • the outer layer coil 25 ⁇ / b> B is not spread outward, and it is difficult to form a defective filling portion of the resin 41 in the cassette coil 21.
  • FIG. 11 schematically shows a part of the stator 1 in a plan view.
  • FIG. 12 schematically shows a part of the stator 1 as viewed in the direction of arrow A in FIG.
  • the poorly filled portions of the mold resin 23 are not adjacent between the cassette coils 21 of the adjacent split stators 2 but adjacent to each other. Insulation resistance does not decrease between the cassette coils 21.
  • a plurality of circular portions arranged on the front surface of each cassette coil 21 indicate unfilled portions 27 that are not filled with the resin 41 due to the contact of the pins 33 described above.
  • the manufacturing cost of the cassette coil 21 can be reduced.
  • the plurality of pins 33 are configured to simply push the rectangular wire 25a at the top of the outer layer coil 25B from the direction in which the coil 25 is accumulated. Therefore, the area for mechanically holding the coil 25 can be reduced, and the fluidity of the resin 41 in the cavity 32 is hardly inhibited by the pins 33. Also in this sense, the occurrence of defective products can be suppressed for the cassette coil 21, and the manufacturing cost of the cassette coil 21 can be reduced.
  • the split stator 2 is manufactured by assembling the cassette coil 21 manufactured as described above to the teeth portion 11b of the split core 11. Therefore, the divided stator 2 having no defect in the cassette coil 21 is obtained. For this reason, generation
  • one stator 1 is manufactured by assembling a plurality of the divided stators 2 manufactured as described above in a ring shape. Therefore, the stator 1 having no defects in the plurality of divided stators 2 assembled in an annular shape is obtained. For this reason, the resin filling defect part does not adjoin the cassette coil 21 of the adjacent divided stator 2. As a result, insulation can be secured for the coils 25 of the adjacent split stators 2 constituting the stator 1. In this sense, the occurrence of defective products can be suppressed for the stator 1, and the manufacturing cost of the stator 1 can be reduced.
  • FIG. 13 is a perspective view schematically showing an insulator 24 in which a coil 25 is set and a main configuration of a mold in this embodiment.
  • This embodiment differs from the first embodiment in the configuration of the mold. That is, a plurality of push pillars 37 for pushing both side surfaces of the coil 25 are provided in the mold cavity.
  • the push pillars 37 are arranged so that the position at which the side surface of the coil 25 is pressed is asymmetric in the plan view of the coil 25. That is, two push pillars 37 are arranged on one side of both sides of the coil 25, and one push pillar 37 is arranged on the other side.
  • a pin (not shown) for pushing the coil 25 downward is provided on the mold in accordance with the arrangement of the push pillars 37.
  • FIG. 14 is a perspective view showing the cassette coil 21 molded by the mold.
  • FIG. 15 schematically shows a part of the stator 1 constituted by the divided stator 2 using the cassette coil 21 of FIG. 14 in a plan view.
  • FIG. 16 schematically shows a part of the stator 1 as viewed from the direction of arrow A in FIG.
  • unfilled portions 27 that are not filled with resin are formed on the side surfaces and the upper surface of the molded cassette coil 21 by contacting the push pillars 37 and the pins.
  • the unfilled portion 27 is disposed so as to be asymmetrical in a plan view of the cassette coil 21. That is, two unfilled portions 27 are disposed on one side of both side surfaces of the cassette coil 21, and one unfilled portion 27 is disposed on the other side.
  • the cassette coils 21 of the adjacent split stators 2 are adjacent to each other. Even so, the unfilled portions 27 of the resin do not contact each other. For this reason, the insulation of the coil 25 can be ensured between the adjacent cassette coils 21.
  • each of the insulator 24, the coil 25, and the split core 11 is manufactured in advance.
  • an insulator 24 is prepared, and then, as shown in FIG. 17 (B), the split core 11 is assembled to the insulator 24. That is, the tooth portion 11 b of the split core 11 is fitted into the cylindrical portion 24 b of the insulator 24.
  • the coil 25 is set on the cylindrical portion 24b of the insulator 24.
  • the divided stator 2 is manufactured by molding the periphery of the coil 25 shown in FIG. 17C with resin. This molding will be described later in detail.
  • the stator 1 is manufactured by assembling a plurality of divided stators 2 in an annular shape.
  • FIG. 18 is a schematic cross-sectional view showing a state where the split core 11, the insulator 24, and the coil 25 are set in the cavity 32 of the mold 31 and then the resin 41 is filled in the cavity 32.
  • 18 is a cross-sectional view similar to FIG.
  • each pin 33 causes one end of the coil 25 in the axial direction (upper part of the coil 25 in FIG. 18) to be opposite to the axial direction (below the coil 25 in FIG. 18) and the coil 25. Press toward the inner center.
  • the coil 25 is resin-molded by filling the cavity 32 with resin while pressing the upper portion of the outer layer coil 25 ⁇ / b> B with the plurality of pins 33 toward the lower side of the coil 25 and the inner center of the coil 25.
  • the resin 41 filled in the cavity 32 of the mold 31 does not enter between the inner layer coil 25A and the outer layer coil 25B. For this reason, the outer layer coil 25 ⁇ / b> B is not spread outward, and it is difficult to form a defective filling portion of the resin 41 in the cassette coil 21.
  • one end of the coil 25 in the axial direction is directed to the opposite side of the axial direction (below the coil 25) and the inner center of the coil 25. Since the resin 41 is filled into the cavity 32 of the mold 31 while being pressed, the resin is difficult to enter between the rectangular wires 25a constituting the coil 25 at the initial stage of filling the resin. For this reason, the rectangular wire 25a of the coil 25 is not pushed outward by the resin 41, and it becomes difficult to form a poorly filled resin portion in the split stator 2. As a result, it is possible to prevent the division stator 2 from being poorly filled with resin, and to ensure the insulation performance of the coil 25. Thereby, generation
  • the position where the coil 25 is pressed by the plurality of pins 33 is left-right symmetric in the plan view of the coil 25, but the pressed position is left-right asymmetric in the plan view. Also good.
  • the rectangular wire 25a is wound in two layers, and the coil 25 including the inner inner layer coil 25A and the outer outer layer coil 25B is used.
  • the coil 25 including the inner inner layer coil 25A and the outer outer layer coil 25B is used.
  • a coil in which a flat wire is wound in a single layer can also be used. In this case, it is possible to prevent the resin from entering between the coil and the insulator, and the same effects as those of the above embodiments can be obtained.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

Dans la présente invention, pour fabriquer une bobine cassette par moulage en résine d'une bobine (25) comprenant un fil plat (25a), la bobine (25) est tout d'abord ajustée dans la cavité (32) d'un moule (31). Ensuite, tout en pressant une extrémité axiale de la bobine (25) avec une broche (33) dans la direction opposée à la direction axiale et vers le centre de la bobine (25), la bobine (25) est moulée en résine par remplissage de la cavité avec une résine (41). Dans ce cas, la surface latérale de la bobine (25) est pressée de manière externe vers le centre de la bobine. Par assemblage de la bobine cassette (21) fabriquée d'une telle manière au noyau divisé (11), un stator divisé (2) est fabriqué. En outre, par assemblage d'une manière circulaire d'une pluralité de stators divisés (2) fabriqués d'une telle manière, un stator unique (1) est fabriqué.
PCT/JP2011/056758 2011-03-22 2011-03-22 Procédé de fabrication pour une bobine cassette, procédé de fabrication pour un stator divisé, et procédé de fabrication pour un stator Ceased WO2012127603A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP2013505678A JP5590219B2 (ja) 2011-03-22 2011-03-22 カセットコイルの製造方法、分割ステータの製造方法及びステータの製造方法
PCT/JP2011/056758 WO2012127603A1 (fr) 2011-03-22 2011-03-22 Procédé de fabrication pour une bobine cassette, procédé de fabrication pour un stator divisé, et procédé de fabrication pour un stator

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/JP2011/056758 WO2012127603A1 (fr) 2011-03-22 2011-03-22 Procédé de fabrication pour une bobine cassette, procédé de fabrication pour un stator divisé, et procédé de fabrication pour un stator

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WO2012127603A1 true WO2012127603A1 (fr) 2012-09-27

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WO (1) WO2012127603A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014111179A3 (fr) * 2013-01-18 2014-09-18 Volkswagen Aktiengesellschaft Bobine et/ou enroulement electrotechnique, procede de fabrication associe et appareil electrique
WO2016051175A1 (fr) * 2014-10-01 2016-04-07 University Of Newcastle Upon Tyne Procédé et système pour la fabrication d'une bobine comprimée
JP2017103844A (ja) * 2015-11-30 2017-06-08 トヨタ自動車株式会社 ２層巻コイルの押圧方法
JP2022520718A (ja) * 2019-02-15 2022-04-01 フラウンホッファー－ゲゼルシャフト ツァー フェーデルング デア アンゲバンテン フォルシュング エー ファー 弦巻線を圧縮することで螺旋状体を生成する方法
DE102022122673A1 (de) * 2022-09-07 2024-03-07 Bayerische Motoren Werke Aktiengesellschaft Herstellverfahren für ein Wicklungsbauteil und Wicklungsbauteil hergestellt mit einem solchen Verfahren

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007143324A (ja) * 2005-11-21 2007-06-07 Toyota Motor Corp 電気モータの分割ステータ
JP2009072055A (ja) * 2007-08-21 2009-04-02 Toyota Motor Corp 分割固定子、モータ、及び分割固定子製造方法
JP2009148060A (ja) * 2007-12-13 2009-07-02 Sumitomo Electric Ind Ltd モールドコイルの製造方法、モールドコイル用金型装置及びモールドコイル

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006187162A (ja) * 2004-12-28 2006-07-13 Sumitomo Electric Ind Ltd ステータおよびその製造方法
JP2009254171A (ja) * 2008-04-08 2009-10-29 Sumitomo Electric Ind Ltd カセットコイルおよびステータ

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007143324A (ja) * 2005-11-21 2007-06-07 Toyota Motor Corp 電気モータの分割ステータ
JP2009072055A (ja) * 2007-08-21 2009-04-02 Toyota Motor Corp 分割固定子、モータ、及び分割固定子製造方法
JP2009148060A (ja) * 2007-12-13 2009-07-02 Sumitomo Electric Ind Ltd モールドコイルの製造方法、モールドコイル用金型装置及びモールドコイル

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014111179A3 (fr) * 2013-01-18 2014-09-18 Volkswagen Aktiengesellschaft Bobine et/ou enroulement electrotechnique, procede de fabrication associe et appareil electrique
CN104904102A (zh) * 2013-01-18 2015-09-09 大众汽车有限公司 电气技术线圈和/或线圈卷、其制造方法以及电气设备
CN104904102B (zh) * 2013-01-18 2018-03-30 大众汽车有限公司 电气技术线圈和/或线圈卷、其制造方法以及电气设备
WO2016051175A1 (fr) * 2014-10-01 2016-04-07 University Of Newcastle Upon Tyne Procédé et système pour la fabrication d'une bobine comprimée
CN107112128A (zh) * 2014-10-01 2017-08-29 泰恩河畔纽卡斯尔大学 用于制造压缩线圈的方法和系统
CN107112128B (zh) * 2014-10-01 2019-08-09 泰恩河畔纽卡斯尔大学 用于制造压缩线圈的方法和系统
US10855152B2 (en) 2014-10-01 2020-12-01 Advanced Electric Machines Group Limited Method and system for manufacture of a compressed coil
JP2017103844A (ja) * 2015-11-30 2017-06-08 トヨタ自動車株式会社 ２層巻コイルの押圧方法
JP2022520718A (ja) * 2019-02-15 2022-04-01 フラウンホッファー－ゲゼルシャフト ツァー フェーデルング デア アンゲバンテン フォルシュング エー ファー 弦巻線を圧縮することで螺旋状体を生成する方法
JP7505787B2 (ja) 2019-02-15 2024-06-25 フラウンホッファー－ゲゼルシャフト ツァー フェーデルング デア アンゲバンテン フォルシュング エー ファー 弦巻線を圧縮することで螺旋状体を生成する方法
DE102022122673A1 (de) * 2022-09-07 2024-03-07 Bayerische Motoren Werke Aktiengesellschaft Herstellverfahren für ein Wicklungsbauteil und Wicklungsbauteil hergestellt mit einem solchen Verfahren

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