JP4519533B2 - Manufacturing method of motor - Google Patents

Description

The present invention relates to a method of manufacturing a motor of , for example, a permanent magnet type.

Conventionally, for example, a motor (see, for example, Patent Document 1) including a cooling pipe through which a coolant passes on the outer periphery of a stator core of a stator is known.
Conventionally, for example, a cooling device that performs cooling by directly contacting cooling oil pumped by a pump with a stator winding (see, for example, Patent Document 2 and Patent Document 3) is known.
In addition, for example, resin is injected in a state where a groove formed on the inner wall surface of the outer rotor cover that houses the outer rotor around which the coil is wound is sealed with a partition plate, and the coil end is covered with the resin, A motor (see, for example, Patent Document 4) that circulates cooling oil in a passage formed by a partition plate and a groove is known.
Japanese Patent Laid-Open No. 9-93869 Japanese Utility Model Publication No. 6-36363 JP 2003-224945 A JP-A-11-206063

However, in the motor provided with the cooling pipe on the outer periphery of the stator core according to the above prior art, a groove for mounting the cooling pipe is formed on the outer periphery of the stator core. It is necessary to secure a thickness for forming the groove with respect to the thickness, which causes a problem that the radial dimension of the motor increases. In addition, since the adhesive for fixing the cooling pipe is interposed in the stator core and the groove between the stator winding as a heat source and the cooling pipe, the cooling efficiency may be lowered.
Also, in a cooling device that performs cooling by directly contacting the cooling oil pumped by the pump according to the above-described prior art with the stator winding, for example, when foreign matter is mixed in the cooling oil, There is a possibility that the insulating coating layer may be damaged. Moreover, in order to inject cooling oil into the windings or to secure a desired flow rate for the cooling oil flowing along a complicated flow path between a plurality of windings, a relatively high output and large size It is necessary to provide a pump, which causes a problem that the apparatus configuration is increased in size.

Further, in the motor that circulates the cooling oil through the passage formed by the groove portion of the outer rotor cover and the partition plate according to the above-described prior art, between the stator winding that is a heat source and the cooling oil flow passage. Since the partition plate is interposed, there is a possibility that the cooling efficiency may be lowered.
This invention is made | formed in view of the said situation, and it aims at providing the manufacturing method of the motor which can improve cooling efficiency, suppressing that a motor enlarges.

In order to solve the above-described problems and achieve the object, a method of manufacturing a motor according to claim 1 includes a rotor, a stator that generates a rotating magnetic field that rotates the rotor, and the stator. The stator is provided on an annular yoke portion (for example, the back yokes 31a, ..., 31a in the embodiment) and an inner peripheral portion or an outer peripheral portion of the yoke portion. Winding mounting portions (for example, teeth 31b,..., 31b, slots in the embodiment) and windings wound on the winding mounting portions (for example, stator windings 32 in the embodiment,... , 32), and the winding mounting portion includes an iron core portion (for example, teeth 31b,..., 31b in the embodiment) and a plurality of through holes penetrating the iron core portion in the axial direction or the iron core portion. A plurality extending along the axial direction with the radial direction of A groove portion (for example, a slot in the embodiment), and the winding is mounted in a plurality of the through holes or the groove portions arranged at predetermined intervals along the circumferential direction of the iron core portion. And a winding transition portion (for example, a winding transition portion 32a,..., 32a in the embodiment) disposed along the end surface in the axial direction of the iron core portion. The resin part (for example, resin mold part 41 in the embodiment) that is formed in an annular shape that covers and extends along the circumferential direction, and the end face of the stator in the rotational axis direction on the outer peripheral surface of the resin part An annular notch portion (for example, the notch portion 42 in the embodiment) extending along the circumferential direction so that the diameter thereof is reduced by one step in the radial direction in the vicinity of the connection portion with the outer peripheral surface of the resin portion. The notch of the resin part is opened. Since the end is closed by the inner peripheral surface of the housing, the periphery is surrounded by the notch portion of the resin portion, the end surface of the stator in the rotation axis direction, and the inner peripheral surface of the housing. In this way, the resin portion is an annular groove having a predetermined shape. The method of manufacturing a motor includes an annular refrigerant channel (for example, the refrigerant channel 43 in the embodiment) formed as described above. The molding die has an outer peripheral inner wall surface having a diameter equal to or slightly larger than the outer diameter of the stator, and the outer peripheral end of the stator is A stator mounting portion for mounting; and a notch portion generating portion having an outer peripheral side inner wall surface having a smaller diameter than the stator mounting portion and disposed at a position shifted to the outer peripheral side from the winding crossover portion; A diameter larger than that of the notch generating portion, The stator having the outer peripheral side inner wall surface having a diameter equal to or slightly larger than the inner diameter of the housing is provided, and the stator around which the winding is wound is mounted at a predetermined position of the molding die. The winding transition part is inserted into the annular concave groove of the molding die, and a predetermined amount of thermoplastic resin or thermosetting molten resin is poured into the molding die, and the winding transition part and the stator The resin part is formed by curing or melting the molten resin by cooling or heating with the end in the rotational axis direction immersed in the molten resin, and taking out the resin part by dividing the mold. The stator is inserted into the housing, the outer peripheral surface of the resin portion abuts on the inner peripheral surface of the housing, and the opening end of the cutout portion of the resin portion is blocked by the inner peripheral surface of the housing. The resin part As features and missing portion, and said end face of said rotational axis direction of the stator, said refrigerant passage of said annular so as to be surrounded by said inner peripheral surface of the housing is defined Yes.

According to the above motor, in the stator housed in the housing, the winding wound around the winding mounting portion of the stator includes the winding main body portion mounted in the through hole or the groove portion of the iron core portion. And a winding crossover portion for connecting different winding main body portions to each other outside the through hole or the groove portion. Then, the winding transition portion is disposed at the end of the iron core portion in the rotation axis direction of the stator, and the refrigerant flow path is directly formed in the resin portion that covers the winding transition portion. Compared with the case where the cooling channel is formed on the outer periphery, it is possible to prevent the radial dimension of the motor from increasing. Moreover, since only the resin portion is interposed between the winding that is the heat generation source and the cooling medium (refrigerant), for example, the cooling efficiency is improved by forming the resin portion with a resin having high thermal conductivity. be able to.
In addition, since the refrigerant flow path is formed in the resin portion covering the winding crossing portion of the winding, for example, compared to the case where the resin portion is not provided and the resin portion, the refrigerant flow is not exposed to the outside of the iron core portion. Since the heat is smoothly radiated in the order of the path and the refrigerant, the heat dissipation of the winding crossing portion can be improved. In addition, by fixing the winding transition part to the iron core part by the resin part, it is possible to suppress the occurrence of vibration of the winding transition part accompanying the operation of the motor.

  According to the above motor, by forming the cooling flow path by the notch provided in the resin part covering the winding transition part, for example, compared with the case where the cooling flow path is formed on the outer periphery of the iron core part, It is possible to prevent the radial dimension from increasing or the radial thickness of the housing from increasing. In addition, by providing the notch in the resin part, the contact area between the refrigerant flowing in the cooling flow path and the resin part can be increased, and the heat dissipation of the winding via the resin part can be improved.

  According to the above motor, when forming the resin portion by resin molding or the like, it is possible to prevent troublesome work such as forming the resin portion and the refrigerant flow path individually. In addition, it is possible to efficiently cool the plurality of winding crossing portions by using the same refrigerant while preventing the refrigerant flow path from becoming complicated.

According to the motor manufacturing method described above, the refrigerant flow path can be easily formed without the need to add a new component such as a flow pipe for circulating the refrigerant inside .

According to the motor manufacturing method of the first aspect of the present invention, the cooling efficiency can be improved while preventing the radial dimension of the motor from increasing. In particular, it is possible to improve the heat dissipation of the winding transition part, and to suppress the occurrence of vibration of the winding transition part accompanying the operation of the motor.
Furthermore, by providing a notch in the resin part, the contact area between the refrigerant flowing through the cooling flow path and the resin part can be increased, and the heat dissipation of the winding via the resin part can be improved.

Furthermore, when forming the resin part by resin molding or the like, it is possible to prevent troublesome work such as forming the resin part and the coolant channel individually. In addition, it is possible to efficiently cool the plurality of winding crossing portions by using the same refrigerant while preventing the refrigerant flow path from becoming complicated.
Furthermore, for example, without the need to add new components, such as flow tube for circulating a coolant therein, it is possible to easily form a coolant channel.

Hereinafter, an embodiment of a motor of the present invention will be described with reference to the accompanying drawings.
The motor 1 according to the present embodiment is a brushless DC motor that is used as a drive source of a vehicle such as a hybrid vehicle or a fuel cell vehicle, and can rotate around a rotation axis O as shown in FIGS. The substantially cylindrical rotor 2, the substantially cylindrical stator 3 having an inner peripheral portion facing the outer peripheral portion of the rotor 2, and the stator 3 so as to cover the outer peripheral surface of the stator 3. And the cylindrical housing 4 which accommodates the rotor 2 inside is comprised.

The rotor 2 is disposed inside the stator 3 and is rotatable around the rotation axis O. For example, the rotor shaft 10 having a substantially cylindrical shape, and the laminated core 11 mounted on the outer peripheral surface of the rotor shaft 10 are provided. The permanent magnets 12 are configured to include a plurality of permanent magnets 12.
The laminated core 11 is formed, for example, by laminating a plurality of electromagnetic steel plates such as a substantially annular silicon steel plate in the direction of the rotation axis O, and a substantially cylindrical rotor core 21 and a predetermined position in the circumferential direction of the rotor core 21. A plurality of salient pole portions 22,..., 22 projecting in a substantially rectangular shape in cross section from the outer peripheral surface to the outer side in the radial direction, and between these salient pole portions 22, 22 adjacent in the circumferential direction, A substantially rectangular plate-like permanent magnet 12 is mounted so as to be sandwiched between the salient pole portions 22 and 22 from both sides.

  Two magnet holding claws 22a and 22a projecting outward in the circumferential direction are formed on the outer peripheral side end of the salient pole part 22, and the magnets holding each other projecting from the salient pole parts 22 and 22 adjacent in the circumferential direction are formed. The claw portions 22a and 22a abut against the outer peripheral surface of the permanent magnet 12 mounted between the salient pole portions 22 and 22, and restrict the permanent magnet 12 from moving outward in the radial direction. . That is, in the motor 1, a part of the outer peripheral surface of the permanent magnet 12 is exposed toward the stator 3.

  The permanent magnet 12 is, for example, a ferrite magnet, or a Nd—Fe—B or Sm—Co rare earth magnet, and is magnetized in the radial direction. The permanent magnets 12 adjacent to each other in the circumferential direction are opposite to each other, that is, the permanent magnet 12 whose outer peripheral side is the north pole is adjacent to the permanent magnet 12 whose outer peripheral side is the south pole. It is arranged to fit. The number of the plurality of permanent magnets 12, ..., 12 is an even number.

  The substantially cylindrical stator 3 is configured by, for example, a plurality of stator pieces 31,..., 31 arranged in a substantially annular shape being accommodated in a housing 4. Each stator piece 31 formed by laminating electromagnetic steel plates in the direction of the rotation axis O includes a back yoke 31a and teeth 31b extending inward in the circumferential direction from the back yoke 31a. 31 b includes a plurality of phases (for example, three phases including a U phase, a V phase, and a W phase) of stator windings 32,..., 32 that generate a rotating magnetic field that rotates the rotor 2. It is wound through.

Of both end portions in the circumferential direction of the back yoke 31a of each stator piece 31, a convex portion 33 protruding in the circumferential direction is formed at one end portion, and the convex portion of the adjacent stator piece 31 is formed at the other end portion. A recess 34 into which the portion 33 can be fitted is formed. Thereby, the stator pieces 31, 31 that are adjacent in the circumferential direction are such that the convex portion 33 of the back yoke 31 a of one stator piece 31 is fitted into the concave portion 34 of the back yoke 31 a of the other stator piece 31. They are positioned and connected and fixed in a predetermined relative arrangement state.
Further, two winding holding claws 31c and 31c projecting outward in the circumferential direction are formed at the inner peripheral end of the teeth 31b of each stator piece 31, and the stator winding wound around each tooth 31b. The line 32 is restricted from moving inward in the circumferential direction.

Of the stator windings 32 wound around the teeth 31b, the windings disposed in the slots between the teeth 31b and 31b adjacent in the circumferential direction are connected to the outside of the slot, that is, the rotation axis of each tooth 31b. The winding transition part 32 a connected on the end face in the O direction is covered with the resin mold part 41.
The resin mold portion 41 is formed, for example, in a substantially cylindrical shape, and is connected to end surfaces 3A, 3A of the stator 3 in the rotation axis O direction (for example, end surfaces of the plurality of teeth 31b, ..., 31b in the rotation axis O direction). Yes. Further, on the outer peripheral surface 41A of the resin mold portion 41, an annular notch portion 42 is formed in the vicinity of the connection portion with the end surfaces 3A and 3A of the stator 3 so as to reduce the diameter by one step in the radial direction. Yes.

The outer peripheral surface 41 </ b> A of the resin mold portion 41 is connected to the inner peripheral surface of the housing 4 that covers the outer peripheral surface of the stator 3. As a result, an annular refrigerant flow path 43 is defined so as to be surrounded by the cutout portion 42 of the resin mold portion 41, the end surface 3A of the stator 3 in the direction of the rotation axis O, and the inner peripheral surface of the housing 4. It is made.
The housing 4 is formed with a refrigerant inflow hole 44a that penetrates the housing 4 at a position vertically above and communicates with the refrigerant flow path 43. The resin mold portion 41 has a rotational axis O at a position vertically below. A refrigerant discharge hole 44 b extending in the direction and penetrating the resin mold portion 41 and communicating with the refrigerant flow path 43 is formed.

Thereby, for example, as shown in FIG. 3, the cooling medium (refrigerant) such as cooling oil supplied to the refrigerant inflow hole 44a of the housing 4 during operation of the motor 1 or the like is substantially annular from the upper side to the lower side in the vertical direction. In the process of flowing through the refrigerant flow path 43, heat is exchanged between the stator winding 32, which is a heat source via the resin mold portion 41, particularly the winding transition portion 32a, and a relatively high temperature state. The stator winding 32 is cooled.
And the refrigerant | coolant which distribute | circulated the inside of the refrigerant flow path 43 is discharged | emitted outside from the refrigerant | coolant discharge hole 44b of the resin mold part 41. FIG.

The housing 4 covering the outer peripheral surface of the stator 3 is formed of a nonmagnetic material such as an aluminum alloy, for example, and the housing 4 is connected to other devices (for example, an internal combustion engine of a vehicle, etc.) at both ends in the direction of the rotation axis O. The flange portions 4a and 4a are formed for connection and fixing. And the stator 3 inserted in this housing 4 is being fixed in the state of being interference-fitted.
That is, the inner diameter of the housing 4 is set so as to have a predetermined allowance with respect to the outer diameter of the stator 3. When the stator 3 is fixed to the housing 4, first, the housing 4 is heated. Then, after the inner diameter of the housing 4 is thermally expanded until the stator 3 can be inserted, the stator 3 is inserted into the housing 4. Next, when the housing 4 is cooled, the inner diameter of the housing 4 is thermally contracted, the stator 3 is tightened, and the fixing of the stator 3 is completed.

And as a manufacturing method of this motor 1, especially the method of forming the resin mold part 41, first, as shown, for example in FIG.4 and FIG.5, the annular groove 51a of a predetermined shape is formed, and it can be divided | segmented. The stator 3 around which the stator winding 32 is wound is mounted at a predetermined position of the formed mold 51, and the winding transition portion 32 a is inserted into the annular groove 51 a of the mold 51.
Next, a predetermined amount of thermoplastic or thermosetting molten resin 52 was poured into the mold 51, and the winding transition portion 32 a and the end of the stator 3 in the direction of the rotation axis O were immersed in the molten resin 52. The molten resin 52 is cured by cooling or heating in the state. Thereby, the resin mold part 41 is formed.
Next, the mold 51 is divided, the resin mold portion 41 is taken out, and the stator 3 is inserted into the housing 4. As a result, the outer peripheral surface 41A of the resin mold portion 41 abuts on the inner peripheral surface of the housing 4, and the opening end of the notch portion 42 of the resin mold portion 41 is closed by the inner peripheral surface of the housing 4, thereby forming an annular shape. The refrigerant flow path 43 is defined.
Next, the rotor 2 is mounted inside the stator 3, and the series of steps is completed.

The molten resin 52 is obtained by mixing glass fibers with a synthetic resin such as an unsaturated polyester resin, and further, for example, a curing agent, a filler, a release agent, a reinforcing agent (for example, , SiC, AlN and other composite ceramics) can be used. Thereby, desired heat resistance and vibration absorbability can be ensured.
Further, as shown in FIG. 5, for example, the annular concave groove 51 a of the mold 51 has an outer peripheral side inner wall surface 61 </ b> A having a diameter equal to or slightly larger than the outer diameter of the stator 3. A stator mounting portion 61 for mounting the outer peripheral side inner wall surface 62A, which has a smaller diameter than the stator mounting portion 61 and is arranged at a position shifted to the outer peripheral side from the winding transition portion 32a of the stator 3. The notch part generating part 62 provided, and a diameter-increased part 63 having an outer peripheral inner wall surface 63A having a diameter larger than that of the notch part generating part 62 and equal to or slightly larger than the inner diameter of the housing 4 are provided. It is configured.

  As described above, according to the motor 1 according to the present embodiment, the coolant flow path 43 is formed by the notch portion 42 of the resin mold portion 41 that covers the winding transition portion 32a. Compared with the case where the refrigerant flow path 43 is formed, it is possible to prevent the radial dimension of the motor 1 from increasing. In addition, since only the resin mold part 41 is interposed between the stator winding 32 that is a heat generation source and the cooling medium (refrigerant), for example, the resin mold part 41 is made of resin having relatively high thermal conductivity. By forming, cooling efficiency can be improved.

In addition, since the coolant channel 43 is formed in the resin mold portion 41 that covers the winding transition portion 32a, for example, the resin mold portion is not exposed to the outside of the slot without the resin mold portion 41 being provided. Since heat is smoothly radiated in the order of 41, the refrigerant flow path 43, and the refrigerant, it is possible to improve the heat dissipation of the winding crossover portion 32a. In addition, by fixing the winding transition part 32 a to the teeth 31 b by the resin mold part 41, it is possible to suppress the occurrence of vibration of the winding transition part 32 a accompanying the operation of the motor 1.
In addition, by providing the resin mold portion 41 with the cutout portion 42, the contact area between the refrigerant flowing through the refrigerant flow path 43 and the resin mold portion 41 is increased, and heat dissipation of the stator winding 32 via the resin mold portion 41 is achieved. Can improve

  Further, since the coolant channel 43 is formed in an annular shape extending in the circumferential direction, when the resin mold portion 41 is formed by resin molding or the like, for example, the resin mold portion 41 and the coolant channel 43 are individually formed. Thus, it is possible to prevent troublesome work. In addition, while preventing the refrigerant flow path 43 from becoming complicated, it is possible to efficiently cool the plurality of winding crossover portions 32a, ..., 32a by using the same refrigerant.

In the above-described embodiment, the refrigerant introduced into the refrigerant flow path 43 is preferable in that it is smoothly discharged due to gravity. Therefore, when the refrigerant is circulated downward from the upper side in the vertical direction in the refrigerant flow path 43. However, the present invention is not limited to this. For example, as shown in FIGS. 6 and 7, the refrigerant may be circulated from the vertically lower side to the upper side in the refrigerant flow path 43.
In the motor 1 according to this modified example, an annular notch 42 is formed on the outer peripheral surface 41A of the resin mold portion 41 at the end in the direction of the rotation axis O so as to reduce the diameter by one step in the radial direction. Yes.
The outer peripheral surface 41A of the resin mold portion 41 is connected to the inner peripheral surface of the housing 4 that covers the outer peripheral surface of the stator 3, and the end surface 41B of the resin mold portion 41 in the rotation axis O direction is the rotation of the housing 4. At the end in the direction of the axis O, it is connected to a flange 4b projecting radially inward from the inner peripheral surface. Thereby, an annular refrigerant flow path 43 is defined so as to be surrounded by the cutout portion 42 of the resin mold portion 41, the inner peripheral surface of the housing 4, and the flange portion 4 b of the housing 4.
In this modification, the refrigerant is circulated upward from the lower side in the vertical direction in the refrigerant flow path 43, so that, for example, even when a gas such as air is mixed into the refrigerant to form bubbles, The moving direction and the flow direction of the refrigerant are substantially the same direction, and the bubbles can be easily discharged to the outside.
In addition, by providing the refrigerant flow path 43 at the end of the resin mold portion 41 in the direction of the rotation axis O, it is possible to promote heat dissipation of the refrigerant itself flowing through the refrigerant flow path 43.

It is a disassembled perspective view of the motor which concerns on one Embodiment of this invention. It is sectional drawing with respect to the circumferential direction of the motor shown in FIG. It is an AA arrow line view shown in FIG. It is a perspective view of the shaping | molding die concerning this embodiment. It is a figure which shows the state which mounted | wore the stator to the shaping | molding die shown in FIG. It is sectional drawing with respect to the circumferential direction of the motor which concerns on the modification of this embodiment. It is an AA arrow directional view shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Motor 2 Rotor 3 Stator 4 Housing 31a Back yoke (yoke part)
31b Teeth (winding mounting part, iron core part)
32 Stator winding (winding)
32a Winding crossing part 41 Resin mold part (resin part)
42 Notch 43 Refrigerant flow path

Claims (1)

A rotor, a stator that generates a rotating magnetic field that rotates the rotor, and a housing that fixes the stator;
The stator includes an annular yoke portion, a winding mounting portion provided on an inner peripheral portion or an outer peripheral portion of the yoke portion, and a winding wound around the winding mounting portion.
The winding mounting portion includes an iron core portion and a plurality of through holes that penetrate the iron core portion in the axial direction or a plurality of groove portions that extend along the axial direction with the radial direction of the iron core portion as a depth direction. ,
The winding is attached to the plurality of through holes or the groove portions arranged at predetermined intervals along the circumferential direction of the iron core portion, and along the axial end surface of the iron core portion. It is provided with a winding crossing part to be arranged,
A resin part that covers the winding transition part and is formed in an annular shape extending in the circumferential direction;
In the outer peripheral surface of the resin portion, an annular notch portion extending in the circumferential direction so as to reduce in diameter one step in the vicinity of the connection portion with the end surface in the rotational axis direction of the stator, and
The outer peripheral surface of the resin portion is in contact with the inner peripheral surface of the housing, and the opening end of the notch portion of the resin portion is closed by the inner peripheral surface of the housing, thereby the notch portion of the resin portion and and said end face of said rotational axis direction of the stator, a manufacturing method of a motor and a refrigerant flow path of annular formed so as to be surrounded by said inner peripheral surface of the housing,
The resin part is formed using a mold that is an annular groove having a predetermined shape and can be divided;
The molding die has an outer peripheral side inner wall surface having a diameter equal to or slightly larger than the outer diameter of the stator, a stator mounting part for mounting the outer peripheral side end of the stator, and a stator mounting part. Has a smaller diameter, a notch portion generating portion comprising an outer peripheral side inner wall surface disposed at a position shifted to the outer peripheral side from the winding crossing portion, and a larger diameter than the notch portion generating portion, An enlarged-diameter portion having an outer peripheral side inner wall surface having a diameter equal to or slightly larger than the inner diameter of the housing,
At the predetermined position of the mold, the stator around which the winding is wound is mounted,
Inserting the winding transition part into the annular groove of the mold,
Pour a predetermined amount of thermoplastic or thermosetting resin into the mold,
The resin part is formed by curing or melting the molten resin by cooling or heating the winding transition part and the end of the rotation axis direction of the stator immersed in the molten resin,
The mold is divided to take out the resin portion, the stator is inserted into the housing, the outer peripheral surface of the resin portion is in contact with the inner peripheral surface of the housing, and the notch portion of the resin portion is Since the open end is closed by the inner peripheral surface of the housing, the notch portion of the resin portion, the end surface of the stator in the rotation axis direction, and the inner peripheral surface of the housing surround the periphery. The method for manufacturing a motor , wherein the annular refrigerant flow path is defined so as to be surrounded .

Images