Method for manufacturing a stator

Abstract

Provided is a method for manufacturing a stator that is disposed opposite a rotor that rotates about a center axis, the method including: a first step of mounting a ring-shaped stator cover on an insulating substrate having an electric circuit pattern, mounting a stator core inside the stator cover of the substrate, mounting a coil around the stator core, and connecting the coil to the electric circuit pattern; a second step of injecting a liquid thermosetting resin into the inside of the stator cover; a third step of curing the thermosetting resin by heating to fix the stator cover, the stator core, and the coil to the substrate; a fourth step of mounting an electronic component on the substrate and connecting the electronic component to the electric circuit pattern; and a fifth step of cutting the mounting region of the substrate, on which the stator cover, the stator core, the coil, and the electronic component are mounted, from a non-mounting region around the mounting region of the substrate.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a stator configured opposite to a rotor that rotates around a central axis. Background Technology

[0002] Previously, motors with stators configured opposite to rotors that rotate around a central axis were known.

[0003] For example, Patent Document 1 discloses an axial clearance type motor having a stator integrally formed from molding resin in a state where nine iron core members are connected in a ring, the iron core members having windings wound around an insulator covering the teeth of the remaining stator core. In the stator of Patent Document 1, a shaft insertion hole for shaft insertion, a pair of bearing housing holes continuously formed with the shaft insertion hole and respectively housing bearings, a substrate mounting step for mounting a circuit board, and a pair of cover fitting steps respectively fitted with bracket covers are integrally formed from molding resin.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2012-182862 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, Patent Document 1 does not describe the electronic components mounted on the circuit board, nor does it describe the specific method for manufacturing the stator. Therefore, there is room for improvement in terms of how easily a stator with electronic components mounted on the circuit board can be manufactured.

[0009] The purpose of this invention is to provide a method for manufacturing a stator that can easily manufacture a stator on which electronic components are mounted on a circuit board.

[0010] Solution for solving the problem

[0011] The stator manufacturing method of the present invention is a method for manufacturing a stator arranged opposite to a rotor rotating around a central axis, comprising: a first step of mounting an annular stator cover on an insulating substrate having a circuit pattern, mounting a stator core inside the stator cover on the substrate, mounting a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin into the inside of the stator cover; a third step of fixing the stator cover, the stator core, and the coil to the substrate by heating and curing the thermosetting resin; a fourth step of mounting electronic components on the substrate and connecting them to the circuit pattern; and a fifth step of cutting off the mounting area of ​​the substrate where the stator cover, the stator core, the coil, and the electronic components are mounted from the non-mounting area around the mounting area of ​​the substrate.

[0012] Invention Effects

[0013] According to the present invention, it is possible to easily manufacture stators on which electronic components are mounted on a circuit board. Attached Figure Description

[0014] Figure 1 This is a perspective view of an axial motor having a stator according to an embodiment of the present invention.

[0015] Figure 2 This is an exploded perspective view of an axial motor with a stator according to an embodiment of the present invention.

[0016] Figure 3 This is a perspective view of the stator coil assembly of the stator according to an embodiment of the present invention.

[0017] Figure 4 This is a perspective view of the stator cover of the stator according to an embodiment of the present invention.

[0018] Figure 5 This is a flowchart illustrating a method for manufacturing a stator according to an embodiment of the present invention.

[0019] Figure 6 This is an exploded perspective view showing the first step of a method for manufacturing a stator according to an embodiment of the present invention.

[0020] Figure 7 This is a perspective view showing the first step of a method for manufacturing a stator according to an embodiment of the present invention.

[0021] Figure 8 This is a perspective view showing the second and third steps of the stator manufacturing method according to an embodiment of the present invention.

[0022] Figure 9 This is a perspective view showing the fourth step of the stator manufacturing method according to an embodiment of the present invention.

[0023] Figure 10 This is a perspective view showing the fifth step of the stator manufacturing method according to an embodiment of the present invention.

[0024] In the picture:

[0025] 1—Rotor, 2—Stator, 11—Shaft, 12—Yoke, 13—Magnet, 14—Yoke, 15—Bearing, 16—Encoder disk, 21—Stator coil assembly, 23—Front cover, 24—Rear cover, 25—Front bolt, 26—Rear bolt, 100—Axial motor, 211—Stator cover, 211A—Groove, 211B—Fastening hole, 212—Base plate, 212A—Connecting part, 212B—Tool frame base plate, 212C—Main base plate, 212D—Slit, 212E—Burst, 212F—Matching hole, 212G—Cut surface, 213—Stator core, 214—Coil, 215—Magnetic sensor, 216—Encoder, 217—Power signal terminal group, 217A—Connector, 217B—Power connector, 218—Resin part, 219—Bearing housing. Detailed Implementation

[0026] Hereinafter, an axial motor and a stator having an embodiment of the present invention will be described with reference to the accompanying drawings. Furthermore, the scope of the present invention is not limited to the following embodiments, and modifications can be made freely within the scope of the technical concept of the present invention. Additionally, in the following drawings, for ease of understanding of each structure, the scale and quantity of each structure may sometimes differ from the scale and quantity of the actual structure.

[0027] <Structure of Axial Motor>

[0028] Reference Figure 1 and Figure 2 The structure of the axial motor 100 having the stator 2 according to an embodiment of the present invention will be described in detail.

[0029] The axial motor 100 has a rotary-driven rotor 1, a stator 2 for rotating the rotor 1, and a bearing 15.

[0030] The rotor 1 has a shaft 11, a magnetic yoke 12, a magnet 13, a magnetic yoke 14, and an encoder disk 16.

[0031] Shaft 11, which connects to yoke 12, encoder disk 16, stator coil assembly 21, and front cover 23, is a rotating shaft (central shaft) that enables rotor 1 to rotate relative to stator 2.

[0032] The magnetic yoke 12 is aligned with one side of the stator coil assembly 21 along the rotation axis. Figure 2 The upper and middle surfaces are opposite each other and are mounted on shaft 11.

[0033] Magnets 13 are arranged circumferentially on the surface of the yoke 12 opposite to the stator coil assembly 21, and on the surface of the yoke 14 opposite to the stator coil assembly 21.

[0034] The magnetic yoke 14 is parallel to the other side of the stator coil assembly 21 in the direction of rotation. Figure 2 The lower and middle surfaces are opposite each other and mounted on shaft 11.

[0035] The encoder disk 16 is located on the surface of the stator coil assembly 21 opposite to the magnetic yoke 14.

[0036] The stator 2 and the rotor 1 are arranged opposite each other in the direction of rotation axis, and the stator 2 has a stator coil assembly 21, a front cover 23 and a rear cover 24.

[0037] The stator coil assembly 21 is disposed between the yoke 12 and the yoke 14. The stator coil assembly 21 and the rotor 1 are arranged opposite each other in the central axis direction. The detailed structure of the stator coil assembly 21 will be described later.

[0038] The front cover 23 houses the magnetic yoke 12 and secures the stator coil assembly 21 by means of the front bolts 25.

[0039] The rear cover 24 houses the magnetic yoke 14 and secures the stator coil assembly 21 by means of the rear bolts 26.

[0040] The bearing 15 is located on the side of the stator coil assembly 21 opposite to the magnetic yoke 12 and the side of the stator coil assembly 21 opposite to the magnetic yoke 14, and rotatably supports the shaft 11.

[0041] <Structure of the stator coil assembly>

[0042] Reference Figures 2 to 4 The structure of the stator coil assembly 21 of the stator 2 according to an embodiment of the present invention will be described in detail.

[0043] The stator coil assembly 21 includes a stator cover 211, a substrate 212, a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC 216, a power signal terminal group 217, and a bearing housing 219.

[0044] The stator cover 211 is annular. Grooves 211A are provided on the stator cover 211 at 90-degree intervals along the circumference. Fastening holes 211B are provided between the grooves 211A on the stator cover 211, into which the front bolt 25 for fastening the front cover 23 and the rear bolt 26 for fastening the rear cover 24 are pressed in.

[0045] The substrate 212 is formed of an insulating material and includes a connecting portion 212A and a main substrate 212C. On the main substrate 212C, a conductive circuit pattern (not shown) is printed, and a stator core 213, a coil 214, a magnetic sensor 215, an encoder sensor IC 216, a power signal terminal group 217, and a bearing housing 219 connected to the circuit pattern are mounted thereon.

[0046] Stator cores 213 are radially mounted on the inner side of the stator cover 211 of the main substrate 212C with the shaft 11 as the center. Multiple stator cores 213 are mounted on the main substrate 212C at intervals along the circumference.

[0047] Coil 214 is mounted around stator core 213 and connected to the circuit pattern of main substrate 212C. Furthermore, stator core 213 and coil 214 are not limited to... Figure 3 The quantity shown can be any number, as long as more than one is set.

[0048] The magnetic sensor 215 is mounted on the stator 2 and stator coil assembly 21 of the main substrate 212C at a position radially away from the axis 11 (central axis) than the stator core 213. The magnetic sensor 215 is surface-mounted on the main substrate 212C via SMT (Surface Mount Technology). The magnetic sensor 215 detects the magnetic field of the coil 214 and outputs an electrical signal corresponding to the detection result to the connector 217A via the circuit pattern of the main substrate 212C.

[0049] The encoder sensor IC216 is mounted radially on the stator 2 and stator coil assembly 21 of the main substrate 212C, closer to the shaft 11 (central shaft) than the stator core 213. The encoder sensor IC216 is surface-mounted on the main substrate 212C via SMT. The encoder sensor IC216 detects the position of the rotor 1 by reading the encoder disk 16 and outputs the corresponding electrical signal to the connector 217A via the circuit pattern of the main substrate 212C.

[0050] The power signal terminal group 217 consists of connector 217A and power connector 217B. The power signal terminal group 217 is surface-mounted to the main substrate 212C via SMT.

[0051] Connector 217A is mounted on main substrate 212C. Signal terminals (not shown) of connector 217A are connected to the circuit pattern of main substrate 212C, and are connected to magnetic sensor 215 and encoder sensor IC 216 via the circuit pattern of main substrate 212C. Connector 217A engages with an object-side connector (not shown) and outputs the electrical signal from magnetic sensor 215 or encoder sensor IC 216 to the outside.

[0052] Power connector 217B is mounted on main substrate 212C. A power terminal (not shown) of power connector 217B is connected to the circuit pattern of main substrate 212C and is connected to coil 214 via the circuit pattern of main substrate 212C. Power connector 217B engages with a peer connector (not shown) and supplies power to coil 214.

[0053] The bearing housing 219 is mounted on the main base plate 212C. The bearing housing 219 has the shaft 11 inserted through it and holds the bearing 15.

[0054] <Stator Manufacturing Method>

[0055] Reference Figure 2 as well as Figures 5 to 10 The manufacturing method of the stator 2 according to an embodiment of the present invention will be described in detail. Furthermore, in Figure 7 The description of the tool frame substrate 212B is omitted.

[0056] First, prepare Figure 6 The substrate 212 shown has a connecting portion 212A in the slit portion 212D that connects the main substrate 212C and the tool frame substrate 212B.

[0057] Here, the substrate 212 is composed of a connecting portion 212A, a tool frame substrate 212B, and a main substrate 212C.

[0058] The main substrate 212C has a fitting hole 212F that extends through the thickness direction of the substrate 212 and is used to fit the stator core 213. The fitting hole 212F is arranged radially with the central axis through which the shaft 11 is inserted as the center. A slit portion 212D that extends through the thickness direction of the substrate 212 is provided between the tool frame substrate 212B and the main substrate 212C.

[0059] Next, as Figure 6 As shown, an annular stator cover 211 is mounted on an insulating main substrate 212C with a circuit pattern. A stator core 213 is mounted inside the stator cover 211 of the main substrate 212C. A coil 214 is mounted around the stator core 213, and the coil 214 is connected to the circuit pattern of the main substrate 212C (first step) (S1). Thus, it becomes... Figure 7 The state shown.

[0060] Furthermore, in the first process, the connecting portion 212A and the recessed portion 211A provided in the stator cover 211 are engaged, and the stator cover 211 is inserted into the slit portion 212D, thereby mounting the stator cover 211 onto the main substrate 212C. As a result, the stator cover 211 can be easily positioned on the substrate 212.

[0061] Furthermore, in the first process, the stator core 213 is mounted on the main substrate 212C by fitting the stator core 213 into the fitting hole 212F. As a result, the stator core 213 can be easily positioned relative to the main substrate 212C.

[0062] Next, as Figure 8 As shown, liquid thermosetting resin is injected into the gap between the stator cover 211 and the coil 214 on the inner side of the stator cover 211 (second step) (S2).

[0063] Next, the resin portion 218 is formed by heating and curing the thermosetting resin, and the stator cover 211, stator core 213, and coil 214 are fixed onto the main substrate 212C (third step) (S3). Before mounting the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 onto the main substrate 212C, the resin portion 218 is formed by heating the thermosetting resin, thereby preventing the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 from being damaged by heating.

[0064] Next, as Figure 9 As shown, relative to Figure 8 The state shown is reversed, and the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217, which are electronic components, are surface-mounted on the main substrate 212C and connected to the circuit pattern of the main substrate 212C (fourth process) (S4). At this time, the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 are surface-mounted on the main substrate 212C by an automated machine such as a chip mounting machine. In addition, the tool frame substrate 212B arranged around the main substrate 212C is supported by the automated machine when it is transported in the automated machine. By setting the tool frame substrate 212B, the substrate 212 can be easily positioned on the conveyor belt in the automated machine.

[0065] Next, as Figure 10 As shown, by cutting the connecting portion 212A, the mounting area of ​​the main substrate 212C, which houses the stator cover 211, stator core 213, coil 214, magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217, is cut from the non-mounting area surrounding the main substrate 212C, i.e., the tool frame substrate 212B (fifth step) (S5). Thus, since the main substrate 212C and the tool frame substrate 212B can be cut by cutting the connecting portion 212A, they can be easily cut.

[0066] By cutting off the connecting portion 212A, burrs 212E remain on the tool frame substrate 212B, and burrs also remain on the cross-section 212G of the connecting portion 212A of the stator coil assembly 21, thus the cross-section 212G is a fracture surface.

[0067] Using the stator coil assembly 21 manufactured by the above-described manufacturing method, to become Figure 2 The stator 2 is manufactured using the configuration shown.

[0068] Thus, according to this embodiment, after the third step of fixing the stator cover 211, stator core 213, and coil 214 onto the main substrate 212C by heating and curing the thermosetting resin, the fourth step of mounting the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 onto the main substrate 212C and connecting them to the circuit pattern is performed. This prevents the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 from being heated at high temperatures due to the heating during the curing of the thermosetting resin, and makes it easy to manufacture the stator coil assembly 21 with the magnetic sensor 215, encoder sensor IC 216, and power signal terminal group 217 mounted on the main substrate 212C.

[0069] Furthermore, according to this embodiment, in the fourth process, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal group 217 are surface-mounted on the main substrate 212C. This allows the automated SMT production line to automate the process of connecting the circuit pattern of the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal group 217 to the main substrate 212C, thereby significantly reducing working time and manufacturing costs.

[0070] The above embodiments should be considered illustrative rather than restrictive in all respects. The scope of the invention is set forth not by the above embodiments, but by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0071] Specifically, in the above embodiment, although the stator coil assembly 21 is disposed on the axial flux motor 100, it is not limited to this, and the stator coil assembly 21 may also be disposed on a motor other than the axial flux motor.

[0072] In addition, although a stator core 213 is provided in the above embodiment, it is not limited to this and the stator core 213 may not be provided.

[0073] Furthermore, in the above embodiment, although electronic components such as magnetic sensor 215, encoder sensor IC 216 and power signal terminal group 217 are surface-mounted on the main substrate 212C, it is not limited to this. Electronic components can also be mounted on the main substrate by mounting methods other than surface mounting, such as through-hole mounting.

[0074] In addition, although the magnetic sensor 215, encoder sensor IC 216 and power signal terminal group 217 are surface-mounted on the main substrate 212C by an automatic machine in the above embodiment, it is not limited to this. The magnetic sensor 215, encoder sensor IC 216 and power signal terminal group 217 can also be mounted on the main substrate 212C by manual operation.

[0075] Furthermore, in the above embodiment, although the magnetic sensor 215, encoder sensor IC 216 and power signal terminal group 217 are mounted on the main substrate 212C as electronic components, it is not limited to this, and any electronic component can be mounted on the main substrate as needed.

[0076] In addition, in the above embodiment, although the magnetic sensor 215 is mounted in the radial direction of the stator 2 and the stator coil assembly 21 at a position farther away from the shaft 11 (central shaft) than the stator core 213, and the encoder sensor IC 216 is mounted in a position closer to the shaft 11 (central shaft) than the stator core 213, it is not limited to this, and the magnetic sensor and encoder can be mounted at any position on the main substrate.

Claims

1. A manufacturing method of a stator which is arranged in opposition to a rotor rotating around a center axis, characterized by comprising: a first step of arranging a ring-shaped stator cover on an insulating substrate having a circuit pattern, arranging a stator core which is a member different from the stator cover on an inner side of the stator cover of the substrate, arranging a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin into an inner side of the stator cover; a third step of fixing the stator cover, the stator core, and the coil to the substrate by curing the thermosetting resin by heating, and mounting the stator cover, the stator core, and the coil on the substrate; a fourth step of mounting an electronic component on the substrate and connecting the electronic component to the circuit pattern; and a fifth step of cutting off a mounting region of the substrate on which the stator cover, the stator core, the coil, and the electronic component are mounted from a non-mounting region around the mounting region of the substrate.

2. The manufacturing method of a stator according to claim 1, characterized in that, in the fourth step, the electronic component is surface-mounted on the substrate.

3. The manufacturing method of a stator according to claim 1 or 2, characterized by further comprising a step of preparing the substrate, the substrate having a connecting portion connecting the mounting region and the non-mounting region in a slit portion provided between the mounting region and the non-mounting region of the substrate and penetrating in a thickness direction of the substrate.

4. The manufacturing method of a stator according to claim 3, characterized in that, in the first step, the connecting portion and a groove portion provided in the stator cover are engaged, and the stator cover is inserted into the slit portion, whereby the stator cover is arranged on the substrate.

5. The manufacturing method of a stator according to claim 3, characterized in that, in the fifth step, the mounting region is cut off from the non-mounting region by cutting off the connecting portion.

6. The manufacturing method of a stator according to any one of claims 1, 2, 4, and 5, characterized in that, in the fourth step, a connector having a power terminal and a signal terminal is mounted as the electronic component on the substrate, and the power terminal and the signal terminal are connected to the circuit pattern.

7. The manufacturing method of a stator according to any one of claims 1, 2, 4, and 5, characterized in that, in the fourth step, a sensor detecting a position of the rotor is mounted as the electronic component on the substrate, and a terminal portion of the sensor is connected to the circuit pattern.

8. The manufacturing method of a stator according to any one of claims 1, 2, 4, and 5, characterized in that, in the first step, the stator core is arranged on the substrate by fitting the stator core into a fitting hole provided in the substrate and penetrating in a thickness direction of the substrate.

9. The manufacturing method of a stator according to any one of claims 1, 2, 4, and 5, characterized in that, the stator and the rotor are arranged in opposition in a direction of the center axis. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 10. The method of manufacturing the stator according to any one of claims 1, 2, 4, 5, characterized by, In the fourth process, the electronic component is installed at a position closer to the center axis than the stator core in the radial direction of the stator or at a position farther from the center axis than the stator core.

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