JP2009142040A - Rotating electric machine and method of manufacturing rotating electric machine - Google Patents

Abstract

An object of the present invention is to suppress damage to signal wiring arranged near a coil end in a rotating electrical machine.
In a motor case (12) of a rotating electrical machine (10), a rotor (14), a stator core (16), a coil winding (18) wound around the stator core (16), and a coil protruding from both axial ends of the stator core (16). A coil end 30 that is resin-molded at the end, a resolver 40 that detects the rotation angle of the rotor 14, a temperature sensor 42 that detects the temperature of the rotating electrical machine 10, a signal wiring 44 connected to the resolver 40 and the temperature sensor 42, a signal A connecting portion 22 for connecting the wiring 44 to the outside of the motor case 12 is provided. Here, in the resin-molded coil end 30, the burr 32 generated at the time of resin molding is left in an annular shape on the inner peripheral side of the coil end and on the inner side in the axial direction from the axial end.
[Selection] Figure 1

Description

  The present invention relates to a rotating electrical machine and a method for manufacturing the rotating electrical machine, and more particularly to a rotating electrical machine in which a coil end is resin-molded and a method for manufacturing the rotating electrical machine.

  In a rotating electrical machine, a molded motor that molds a stator portion with a resin is used from the viewpoints of reduction in size and weight, reduction in magnetic sound, improvement in insulation characteristics under high humidity and contamination, and the like.

  For example, in Patent Document 1, as a method of manufacturing a resin mold motor, a thermosetting resin in which a filler is mixed is injected from a gate of a molding die by holding the inner diameter of a stator core in a molding die as a guide and holding the column. It is stated that it is solidified and an insulating jacket is formed on the outer periphery of the winding and the stator core. Here, in order to prevent damage to the stator winding during resin molding, the stator core is fitted into the lower mold along the support, and the upper mold is placed on the support so that the pin gate for resin injection is adjacent to the stator core. It is disclosed to be positioned in a gap with the coil end.

  In Patent Document 2, as a mold motor manufacturing method, after inserting a stator core containing windings into a lower mold core, the upper mold is closed, and a resin is injected from the gate using a molding machine or the like and cured. It is stated that it will be taken out later. Conventionally, since the gate is provided on the coil end side on the outer peripheral side of the stator core, the injected resin hits the coil end. Here, the gate is on the outer peripheral side of the stator core, but the stator core It is disclosed that it is provided at a quarter of the stacking thickness.

  In both Patent Documents 1 and 2, both the stator core and the coil end are integrally molded, but there are other molded motors that mold only the coil end portion. According to the configuration in which only the coil end is molded, the stator can be positioned with respect to the motor case by using the outer periphery of the stator core and the inner periphery of the motor case.

JP 05-056610 A Japanese Patent Laid-Open No. 06-022513

  In a rotating electrical machine, a plurality of signal lines connected to, for example, a resolver, a temperature sensor, and the like are arranged in a motor case in addition to a winding terminal drawn from a coil winding wound around a stator core. These signal wirings are often arranged not on the outer periphery of the stator core but on the coil end side. Therefore, if the burr at the notch of the mold inlet when molding the coil end interferes with the signal wiring, the signal line may be damaged.

  An object of the present invention is to provide a rotating electrical machine and a method of manufacturing the rotating electrical machine that can suppress damage to signal wirings arranged in the vicinity of a coil end.

  A rotating electrical machine according to the present invention is a stator core around which a coil winding is wound, a coil end protruding from the axial outer side of the stator core, and a coil end molded with resin, A signal wiring disposed outside the resin-molded coil end in the axial direction, and the resin-molded coil end is a burr after removing the resin inlet when molded with resin, It has a burr | flash arrange | positioned on the inner peripheral side of an end and an axial direction inner side rather than the axial direction end of a coil end, It is characterized by the above-mentioned.

  In the rotating electrical machine according to the present invention, it is preferable that the resin-molded coil end has an annular burr along the inner peripheral side of the coil end.

  The rotating electrical machine according to the present invention may include a motor case body that holds the outer periphery of the stator core, and the stator core may be resin-molded only in the coil winding portion and may not have a resin mold on the outer periphery. preferable.

  The method for manufacturing a rotating electrical machine according to the present invention is a step of resin molding including a coil end protruding from the axial direction of a stator core, the coil winding protruding from the inner side of the coil end. In addition, the step of placing the resin coil on the coil winding portion by placing the coil end axially inside the axial end of the coil end, and the resin portion of the resin injection gate and the coil winding mold at the resin injection port And a step of cutting the portion.

  According to at least one of the above-described configurations, the rotating electrical machine includes a coil end molded with a resin and a signal wiring disposed outside the resin-molded coil end in the axial direction. The burr after removing the resin inlet when molded by is arranged on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end. Accordingly, the burr at the notch of the mold inlet when molding the coil end does not interfere with the signal wiring, and damage to the signal wiring arranged near the coil end can be suppressed.

  Moreover, in the rotating electrical machine, the resin-molded coil end burrs have an annular shape along the inner peripheral side of the coil end. Therefore, if this burr is in an annular shape at the axial end of the coil end, it is likely to cause interference with the signal wiring arranged on the outer side in the axial direction of the coil end. According to the above configuration, even an annular burr does not interfere with the signal wiring.

  In the rotating electrical machine, the outer periphery of the stator core is held by the motor case body, and the outer periphery does not have a resin mold. Thereby, it is possible to suppress interference between the burr of the resin-molded coil end and the signal wiring while accurately positioning the stator core and the motor case.

  Further, the method of manufacturing the rotating electrical machine includes a resin injection port on the inner peripheral side of the coil end and the coil end when the resin mold is performed including the coil end protruding from the axial direction of the stator core. It arrange | positions in the axial direction inner side rather than the axial direction end. Then, the resin portion of the resin injection gate and the coil winding mold portion are cut at the resin injection port. Thereby, the position of the burr near the resin injection port can be set on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end. Therefore, the burr at the notch of the mold inlet when molding the coil end does not interfere with the signal wiring, and damage to the signal wiring arranged near the coil end can be suppressed.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Below, although a three-phase synchronous motor is demonstrated as a rotary electric machine, the rotary electric machine of a format other than this may be sufficient. For example, a generator, an induction motor, or the like may be used. In the following description, the rotating electrical machine will be described as having a resolver and a temperature sensor built into the motor case, but these are examples of the function of signal wiring in the motor case, Any rotating electrical machine in which the signal wiring is arranged in the motor case may be used. In some cases, even if there are no parts requiring signal wiring in the motor case, the signal wiring may be in the motor case and may be a rotating electrical machine disposed in the vicinity of the molded coil end. In the following description, it is assumed that the outer periphery of the stator core is not resin-molded and the outer periphery of the stator core is held by the motor case. However, the stator core may be resin-molded including the outer periphery of the stator core. Good. In this case, generally, the resin injection port is often provided on the outer peripheral side of the stator core, but the present invention is used when the resin injection port cannot be provided on the outer peripheral side of the stator core for other reasons. Can be applied.

  FIG. 1 is a cross-sectional view of the rotating electrical machine 10. The rotating electrical machine 10 is a three-phase synchronous motor, and includes a motor case 12 and many elements housed in the motor case 12. The motor case 12 includes the following elements. That is, the rotor 14, the stator core 16, the coil winding 18 wound around the stator core 16, the coil ends protruding from both axial ends of the stator core 16 and resin-molded coil ends 30, the rotor 14, a resolver 40 that detects the rotation angle of the motor 14, a temperature sensor 42 that detects the temperature of the rotating electrical machine 10, a signal wiring 44 connected to the resolver 40 and the temperature sensor 42, and a signal wiring 44 for connecting the signal wiring 44 to the outside of the motor case 12. A connecting portion 22 is provided in the motor case 12.

  As described above, the motor case 12 is a component that forms an internal space in which the elements constituting the rotating electrical machine 10 are accommodated. The motor case 12 may be configured by combining two metal cylinders having an opening on one side, or by combining a metal cylinder having an opening on one side and a cover disc having a size covering the opening. it can.

  The rotor 14 is a rotor of the rotating electrical machine 10, and for example, a rotor having a configuration in which permanent magnets are arranged on the outer periphery can be used. The central axis of the rotor 14 is an output shaft of the rotating electrical machine 10 and is connected to a load (not shown).

  The stator core 16 is a component that constitutes the stator of the rotating electrical machine 10 together with the coil winding 18. Since the stator is also called a stator, the stator core 16 can be called a stator core. The stator iron core 16 has a shape in which a plurality of convex poles called teeth and slots, which are spaces between adjacent teeth, are alternately arranged along the circumferential direction on the inner peripheral side. The coil winding 18 is wound around each tooth using this slot. As the stator core 16, a laminate of electromagnetic steel plates punched into a predetermined shape can be used.

  The coil winding 18 is a conductive wire with an insulating film wound around each tooth of the stator core 16 as described above. The coil winding 18 has a shape protruding beyond the stator core 16 on the outer sides of both ends in the axial direction of the stator core, and this portion is called a coil end. In FIG. 1, a portion where a lead wire is attached as the coil winding 18 corresponds to a coil end. In the case of a three-phase synchronous motor, the coil winding 18 is pulled out from the coil end using a suitable means such as a bus bar, and is guided to the outside of the motor case 12 using a terminal block (not shown). Connected to cables etc.

  The resin-molded coil end 30 is a coil end portion when the coil winding 18 is resin-molded. As described above, the coil winding 18 is wound around each tooth by using the slots of the stator core. Therefore, when the coil end portion is resin-molded, resin is also placed in the slots of the stator core 16. The entire coil winding 18 is resin molded. In FIG. 1, the resin mold portion inside the stator core 16 is not shown, so that the resin-molded coil end 30 is shown as a representative of the resin mold of the coil winding 18.

  In the resin mold, after resin molding, the resin injection gate and the coil winding mold part are cut at the resin injection port. Therefore, a burr that is not cut for cutting is left at the cut resin inlet. In FIG. 1, the position of the burr 32 is shown. That is, the burr 32 is disposed on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end. The axial direction is a direction in which the output shaft of the rotor 14 extends and is a direction perpendicular to the circumferential direction of the rotor 14. In other words, the position of the resin injection port is set so that the burr 32 does not exist at the axial end of the resin-molded coil end 30.

  The resolver 40 is a sensor that detects the rotation angle of the rotor 14 and the like, and is disposed in the motor case 12 at a position close to the rotor 14. In the example of FIG. 1, the resin-molded coil end 30 is disposed outside the axial end. The resolver 40 is connected to the connection unit 22 by a signal wiring 44, and the detection signal is transmitted to the outside.

  The temperature sensor 42 is a sensor that detects the temperature of the rotating electrical machine 10 and is disposed in the vicinity of the stator core 16 or the resin-molded coil end 30 inside the motor case 12. In the example of FIG. 1, the resin-molded coil end 30 is disposed outside the axial end. Specifically, the temperature sensor 42 detects the temperature in the motor case 12. Alternatively, the temperature of the stator core 16 may be detected, or the temperature of the coil winding 18 may be detected. The temperature sensor 42 is connected to the connecting portion 22 by a signal wiring 44, and the detection signal is transmitted to the outside.

  The signal wiring 44 is a wiring that connects the resolver 40, the temperature sensor 42, and the connection unit 22. Specifically, it can be constituted by an assembly in which several signal lines are in a separated state, or a wire harness in which several signal lines are housed in one protective tube. The signal wiring 44 is disposed outside the molded coil end in the axial direction because of the arrangement of the resolver 40 and the temperature sensor 42.

  As described above, in the resin-molded coil end 30, the burrs 32 generated during the resin molding are arranged on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end. Therefore, the burr 32 is prevented from interfering with the signal wiring 44 and damaging the signal wiring 44.

  FIGS. 2 to 4 are diagrams for explaining a resin molding procedure related to the stator core 16 and the coil winding 18 in the manufacturing method of the rotating electrical machine 10. In the following, the same elements as those in FIG. 1 are denoted by the same reference numerals, and detailed description thereof is omitted. In the following, description will be made using the reference numerals in FIG.

  First, the coil winding 18 is wound around the stator core 16 (coil winding winding step). Here, as described above, the coil winding 18 is wound around each tooth using the slot of the stator core 16. The wound coil winding 18 projects outward in the axial direction of the stator core 16 to form a coil end. This is shown in FIG.

  Next, resin molding is performed on the coil winding 18 using the resin mold 50 (resin molding step). As shown in FIG. 3, the resin mold 50 has a gate 60 to which molten resin is supplied, and a resin injection port 52 extending from the gate 60 is formed at a coil end portion of the stator core 16. Provided.

  The resin injection port 52 is arranged on the inner peripheral side rather than the outer peripheral side of the coil end so that the injected resin flows in the axial direction in the slots of the stator core 16 and easily flows toward the coil end on the opposite side. Provided. Further, in consideration of the position of the burr generated in the next cutting step, the burr is provided on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end.

  In addition, about the axial direction edge part of a coil end, it is preferable to devise the shape of the resin mold metal mold | die 50 so that it may become a smooth shape without a corner | angular part. As a result, the signal wiring 44 can be prevented from being damaged by the outer shape of the resin-molded coil end 30.

  The resin mold 50 has a structure in which the outer peripheral side of the stator core 16 is held in close contact so that the resin does not flow around the outer peripheral side of the stator core 16. As a result, resin molding is performed only on the coil winding 18, and the stator core 16 does not have a resin mold on the outer periphery thereof.

  When molten resin pressurized from a resin molding machine (not shown) is supplied to the gate 60 of the resin mold 50, the molten resin flows from the resin injection port 52 into the cavity of the coil end portion, and the stator core. Flow through 16 slots to fill the cavity of the opposite coil end portion. In this way, the portion of the coil winding 18 including the coil end portion is resin-molded.

  When the resin molding is performed in this manner, the resin portion of the resin injection gate and the coil winding mold portion are then cut at the resin injection port (cutting step). Cutting can be performed using a cutting tool such as a suitable cutter or a notch such as pliers. FIG. 4 shows this state, and the resin portion 62 of the resin supply gate and the resin-molded coil end 30 are separated. The cut or notched portion is a protrusion. This burr can be appropriately rounded or the like, but takes a lot of work, and even in this case, the burr 32 may remain. As described above, the burr 32 is left on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end, but is not left on the axial end of the resin-molded coil end 30. .

  In this way, a stator having a resin-molded coil end 30 is manufactured, and assembled into the motor case 12 together with the rotor 14, the resolver 40, the temperature sensor 42, the signal wiring 44, etc., and the rotating electrical machine 10 is manufactured. .

  FIG. 5 is a diagram for explaining the operational effect of the rotating electrical machine 10 manufactured as described above, in particular, the operational effect of the arrangement of the burr 32 left on the resin-molded coil end 30. FIG. 5 is a schematic diagram showing a state in which the signal wiring 44 is arranged on the stator having the stator core 16 and the resin-molded coil end 30. Here, illustration of a sensor such as a resolver is omitted. In the resin-molded coil end 30, the burrs 32 generated during the resin molding are left in an annular shape on the inner peripheral side of the resin-molded coil end 30 and on the inner side in the axial direction from the axial end. The signal wiring 44 is disposed on the outer side in the axial direction of the resin-molded coil end 30. Therefore, even if the deburring process is omitted, the signal wiring 44 does not contact the burr 32 and damage due to the burr 32 can be suppressed.

It is sectional drawing of the rotary electric machine in embodiment which concerns on this invention. It is a figure explaining a coil winding winding process among the manufacture procedures of the rotary electric machine in embodiment which concerns on this invention. It is a figure explaining the resin mold process among the manufacture procedures of the rotary electric machine in embodiment which concerns on this invention. It is a figure explaining the cutting process in the place of a resin injection hole among the manufacture procedures of the rotary electric machine in embodiment which concerns on this invention. In embodiment which concerns on this invention, it is a figure explaining the effect regarding the position of a burr | flash.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Rotating electrical machine, 12 Motor case, 14 Rotor, 16 Stator core, 18 Coil winding, 22 Connection part, 30 Resin molded coil end, 32 Burr, 40 Resolver, 42 Temperature sensor, 44 Signal wiring, 50 Resin mold Mold, 52 Resin inlet, 60 gate, 62 Resin portion of resin supply gate.

Claims (4)

A stator core wound with coil windings;
A coil end in which a coil winding protrudes outside the stator core in the axial direction, and a coil end molded by resin;
A signal wiring disposed outside the resin-molded coil end in the axial direction;
With
The resin-molded coil end
It is a burr after removing the resin inlet when molded with resin, and has a burr arranged on the inner peripheral side of the coil end and on the inner side in the axial direction than the axial end of the coil end. A rotating electric machine that is characterized In the rotating electrical machine according to claim 1,
The resin-molded coil end
A rotating electrical machine having an annular burr along an inner peripheral side of a coil end. In the rotating electrical machine according to claim 1 or 2,
It has a motor case body that holds the outer periphery of the stator core,
The stator iron core is a rotating electrical machine characterized in that only a coil winding portion is resin-molded and the outer periphery does not have a resin mold. A resin molding step including a coil end protruding from the axial direction of the stator core, the coil end projecting from the inner end side of the coil end, and the axial direction of the coil end relative to the axial end of the coil end. A step of resin molding with respect to the coil winding portion, arranged inside in the direction;
Cutting the resin portion of the resin injection gate and the coil winding mold portion at the resin injection port;
The manufacturing method of the rotary electric machine characterized by including.

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