Terminal positioning jig and stator molding device

Abstract

The invention provides a terminal positioning jig which can easily ensure the position accuracy of an external connection terminal of a stator. A terminal positioning jig (50) is attached to a molding die (40) for resin-molding a stator (12) provided with a stator core (14), a coil (16), and a bus bar unit (18). The terminal positioning jig (50) has a terminal positioning portion (60) that contacts a plurality of terminal portions (24) of the bus bar unit (18) and positions the plurality of terminal portions (24) with respect to the molding die (40).

Description

Technical Field

[0001] The present disclosure relates to a terminal positioning jig attached to a molding die for resin-molding a stator, and a stator molding apparatus including the terminal positioning jig. Background Art

[0002] Japanese Unexamined Patent Application Publication No. 2010-75010 discloses a terminal structure of a rotating electrical machine, in which a coil end portion is resin-molded to form a resin molding portion, and a terminal portion integrated with the resin molding portion is provided. In the terminal structure of the rotating electrical machine, the terminal portion includes a resin terminal plate that holds a metal terminal connected to the outside. During resin molding, the terminal plate is held by a pin or the like provided in the molding die, whereby the terminal is positioned in the molding die. Summary of the Invention

[0003] Problems to be Solved by the Invention

[0004] However, due to the resin temperature, resin pressure, heating when curing the resin, load from the molding die, etc. during resin molding, the resin terminal plate deforms, and thus it is difficult to sufficiently prevent deterioration of the positional accuracy of the metal terminal (i.e., the external connection terminal) after resin molding.

[0005] In consideration of the above facts, an object of the present disclosure is to obtain a terminal positioning jig and a stator molding apparatus that can easily ensure the positional accuracy of the external connection terminals of the stator.

[0006] Solutions to the Problems

[0007] The terminal positioning jig according to the first aspect is attached to a molding die for resin-molding a stator, the stator including: a stator core; a coil wound around teeth of the stator core; and a bus bar unit having a plurality of bus bars electrically connected to the coil, the terminal positioning jig having: a terminal positioning portion that contacts an external connection terminal included in the bus bar unit and positions the external connection terminal relative to the molding die.

[0008] In the first aspect, the terminal positioning jig is attached to a molding die for resin-molding a stator, the stator including a stator core, a coil, and a bus bar unit. The terminal positioning jig has a terminal positioning portion that contacts an external connection terminal included in the bus bar unit and positions the external connection terminal relative to the molding die. Thus, since the terminal positioning portion of the terminal positioning jig attached to the molding die directly contacts the external connection terminal, it is easier to ensure the positional accuracy of the external connection terminal than a configuration in which the external connection terminal is positioned in the molding die via a resin member.

[0009] The terminal positioning fixture of the second solution, in the first solution, includes: a fixture main body disposed radially outside the stator; and a terminal pressing portion fixed to the fixture main body in the axial direction of the stator. The terminal positioning portion is configured to sandwich the external connection terminal between the fixture main body and the terminal pressing portion.

[0010] In the terminal positioning fixture of the second solution, the fixture main body is disposed radially outside the stator, and the terminal pressing portion is fixed to the fixture main body in the axial direction of the stator. In the terminal positioning portion of this terminal positioning fixture, the external connection terminal is sandwiched between the fixture main body and the terminal pressing portion, so that the external connection terminal can be positioned with high precision in the axial direction of the stator.

[0011] The terminal positioning fixture of the third solution, in the first solution or the second solution, the terminal positioning portion has: a concave portion formed in at least one of the fixture main body and the terminal pressing portion, for the external connection terminal to be inserted along the axial direction of the stator.

[0012] In the terminal positioning fixture of the third solution, the terminal positioning portion has a concave portion formed in at least one of the fixture main body and the terminal pressing portion. The external connection terminal is inserted into this concave portion along the axial direction of the stator. Thus, for example, the external connection terminal can be positioned in the circumferential direction of the stator.

[0013] The terminal positioning fixture of the fourth solution, in any one of the first solution to the third solution, the terminal positioning fixture can be detached from the molding die.

[0014] According to the fourth solution, the terminal positioning fixture can be detached from the molding die. Therefore, for example, in a state where the terminal positioning fixture is detached from the molding die, disassembly and assembly of the stator relative to the terminal positioning fixture can be performed, and the workability is improved.

[0015] The stator molding device of the fifth solution is used for resin molding of a stator. The stator includes: a stator core; a coil wound around teeth of the stator core; and a bus bar unit in which a plurality of bus bars electrically connected to the coil are integrally formed by resin. The stator molding device includes: a molding die; and a terminal positioning fixture according to any one of the first solution to the fourth solution attached to the molding die.

[0016] In the stator molding device of the fifth solution, resin molding is performed on the stator, and the stator includes a stator core, a coil, and a bus bar unit. The stator molding device includes a molding die and a terminal positioning fixture attached to the molding die. This terminal positioning fixture is a terminal positioning fixture according to any one of the first solution to the fourth solution, so the above effects can be obtained.

[0017] Advantages of the Invention

[0018] As described above, in the terminal positioning jig and the stator molding device of the present disclosure, it is possible to easily ensure the positional accuracy of the external connection terminals of the stator. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a perspective view of the stator molding device and the stator of the embodiment.

[0020] Figure 2 It is a perspective view of the stator of the embodiment.

[0021] Figure 3 It is a perspective view of the state of the stator before resin molding of the embodiment.

[0022] Figure 4 It is a perspective view of the state during the attachment of the stator to the terminal positioning jig of the embodiment.

[0023] Figure 5 It is a perspective view of the state where the attachment of the stator to the terminal positioning jig of the embodiment is completed.

[0024] Figure 6 It is a side view of the state during the attachment of the stator to the terminal positioning jig of the embodiment.

[0025] Figure 7 It is viewed from the axial direction of the stator Figure 6 The state of a part of the shown configuration is a top view. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] Hereinafter, a stator molding device 10 according to an embodiment of the present disclosure will be described. Note that, in each figure, in order to make the drawings easy to observe, some reference numerals may be omitted. Figures 1 to 7 For example, as

[0027] As Figure 1 shown, the stator molding device 10 of the present embodiment is a device for resin molding a stator 12, and includes: a molding die 40 having a lower die 42 and an upper die 44; and a terminal positioning jig 50 attached to the molding die 40.

[0028] For example, as Figure 2 and Figure 3As shown, the stator 12 is an armature (stator) including a stator core 14, a plurality of coils 16, an insulator (not shown), a bus bar unit 18, and a potting resin 28. The stator core 14, the plurality of coils 16, the insulator, the bus bar unit 18, and the potting resin 28 are accommodated in a cylindrical housing 30. An unshown rotor is disposed inside the stator 12 to form an inner rotor type motor (rotating electric machine). An example of this motor is a three-phase motor, which is a resin molded motor obtained by potting the stator core 14, the plurality of coils 16, the insulator, and the bus bar unit 18 with the potting resin 28.

[0029] The stator core 14 is formed by laminating a plurality of iron core sheets made of electromagnetic steel sheets. The stator core 14 is formed in a ring shape and has a yoke 14A and a plurality (here, 24) of teeth 14B. The stator core 14 may be divided into a plurality of parts in the circumferential direction. The yoke 14A is in a cylindrical shape. The plurality of teeth 14B are formed to protrude from the inner circumferential surface of the yoke 14A toward the inside in the radial direction of the stator core 14. The plurality of teeth 14B are arranged at equal intervals in the circumferential direction of the stator core 14, and slots (reference numerals omitted) are respectively formed between the plurality of teeth 14B. The stator 12 is fitted inside the housing 30. It should be noted that Figure 3 the number of poles and the number of slots of the shown stator 12 are merely examples and are not limited thereto. In addition, depending on the specifications of the motor, the housing 30 may be unnecessary as a constituent element.

[0030] The plurality of coils 16 are respectively wound around the plurality of teeth 14B in a spiral shape. An insulator is interposed between each coil 16 and each tooth 14B. It should be noted that an insulating material such as insulating paper or varnish may be interposed between each coil 16 and each tooth 14B instead of the insulator. Each coil 16 has the following structure: for example, a strand made of a wire material such as copper, aluminum, silver, or their alloy is covered with an insulating material such as enamel. The strand is a round wire here, but it may also be a flat wire, a hexagonal wire, or the like. When viewed from the radial direction of the stator core 14, the coil 16 is wound into a substantially rectangular shape with the axial direction of the stator core 14 as the long dimension.

[0031] The plurality of coils 16 are composed of a plurality (here, 8) of U-phase coils, a plurality (here, 8) of V-phase coils, and a plurality (here, 8) of W-phase coils. Along the circumferential direction of the stator core 14, they are arranged in the order of U-phase coils, V-phase coils, and W-phase coils in sequence. Each pair of U-phase coils, each pair of V-phase coils, and each pair of W-phase coils are respectively connected to the teeth 14B of the stator core 14 at intervals in the circumferential direction of the stator core 14. Then, adjacent coils 16 of the same phase (the same phase among U-phase, V-phase, and W-phase) are electrically connected to each other through the bus bar unit 18.

[0032] The bus bar unit 18 is adjacently disposed on one side in the axial direction with respect to the stator core 14. The bus bar unit 18 is composed of a U-phase bus bar, a V-phase bus bar, and a W-phase bus bar (both not shown in the figure) and an insulating resin 20. The U-phase bus bar, the V-phase bus bar, and the W-phase bus bar correspond to the "plurality of bus bars" in the present disclosure, and the insulating resin 20 corresponds to the "resin" in the present disclosure. As an example, the U-phase bus bar, the V-phase bus bar, and the W-phase bus bar are manufactured by stamping a metal plate. The U-phase bus bar, the V-phase bus bar, and the W-phase bus bar respectively extend annularly along the yoke 14A in the circumferential direction of the stator core 14. The insulating resin 20 is annular and covers the U-phase bus bar, the V-phase bus bar, and the W-phase bus bar.

[0033] The U-phase bus bar, the V-phase bus bar, and the W-phase bus bar have a plurality of coil connection portions 22 that extend radially inward of the stator core 14 and expose to the outside of the insulating resin 20. The plurality of coil connection portions 22 extend toward the root side of each tooth 14B and are electrically connected to the U-phase coil, the V-phase coil, and the W-phase coil, respectively. In addition, the U-phase bus bar, the V-phase bus bar, and the W-phase bus bar have a U-phase terminal portion 24U, a V-phase terminal portion 24V, and a W-phase terminal portion 24W that extend radially inward of the stator core 14 and expose to the outside of the insulating resin 20. Bolt holes 26 are respectively formed in the U-phase terminal portion 24U, the V-phase terminal portion 24V, and the W-phase terminal portion 24W. The U-phase terminal portion 24U, the V-phase terminal portion 24V, and the W-phase terminal portion 24W correspond to the "external connection terminals" in the present disclosure. These U-phase terminal portion 24U, V-phase terminal portion 24V, and W-phase terminal portion 24W are connected to a three-phase power supply, and thus the stator 12 configured as described above functions as a stator of a three-phase motor. Hereinafter, the U-phase terminal portion 24U, the V-phase terminal portion 24V, and the W-phase terminal portion 24W will be referred to as the "plurality of terminal portions 24".

[0034] The potting resin 28 is a molding resin that pottings the stator core 14, the plurality of coils 16, the insulator, and the bus bar unit 18. The potting resin 28 is, for example, a resin obtained by kneading a powder of a non-magnetic body as a filler in a thermosetting resin such as an epoxy resin or a thermoplastic resin, and has thermal conductivity and insulation. The potting resin 28 can be configured to have higher thermal conductivity than the insulating resin 20 and have a cylindrical outer shape.

[0035] As described above, the stator molding device 10 for molding the above-mentioned sealing resin 28 includes a molding die 40 and a terminal positioning jig 50. The lower die 42 of the molding die 40 has: a rectangular plate-shaped base 42A; a cylindrical core portion 42B formed on the upper surface of the base 42A; and a plurality of positioning pins 42C erected on the upper surface of the base 42A on the radially outer side of the core portion 42B. The core portion 42B is cylindrical with the plate thickness direction of the base 42A as the axial direction. The plurality of positioning pins 42C are cylindrical with the plate thickness direction of the base 42A as the axial direction and are arranged in the circumferential direction of the core portion 42B. It should be noted that the plurality of positioning pins 42C may also be provided on the upper die 44.

[0036] The upper die 44 of the molding die 40 has a cylindrical core portion 44B formed on the upper surface of the base 44A. A flow path for the molding resin is formed in the base 44A. The core portion 44B is cylindrical with the plate thickness direction of the base 44A as the axial direction and is coaxially arranged with the core portion 42B of the lower die 42. When the stator 12 is resin-molded by the molding die 40, the stator 12 before resin molding is clamped between the base 42A of the lower die 42 and the base 44A of the upper die 44, and the core portion 42B and the core portion 44B are inserted into the inside of the stator 12. In this state, the molding resin is filled between the core portion 42B and the stator 12 and between the core portion 44B and the stator 12 from the flow path of the base 44A. This resin molding is performed in a state where the stator 12 is attached to the terminal positioning jig 50.

[0037] As Figures 4 to 5 shown, the terminal positioning jig 50 can be attached / detached relative to the lower die 42 of the molding die 40 as an example. The terminal positioning jig 50 includes: a jig main body 52 disposed (attached) on the radially outer side with respect to the stator 12; and a terminal pressing portion 70 that holds a plurality of terminal portions 24 of the stator 12 on the jig main body 52. The jig main body 52 is formed of metal, for example, and is configured as a cylindrical shape by combining a first split body 54 and a second split body 56 that are semi-circular arc-shaped. The first split body 54 and the second split body 56 are in a shape that divides the cylinder into two halves. The first split body 54 and the second split body 56 are fastened with a plurality of bolts (not shown). It should be noted that in Figure 4 and Figure 5 , a plurality of holes 58 formed on the outer peripheral surface of the first split body 54 are holes for inserting the above-mentioned bolts.

[0038] The inner diameter of the fixture body 52 is set to be approximately the same as the outer diameter of the stator 12, and the axial dimension of the fixture body 52 is set to be approximately the same as the axial dimension of the stator 12. When the stator 12 is attached to the fixture body 52, the stator 12 is disposed between the first split body 54 and the second split body 56, and the first split body 54 and the second split body 56 are fastened by a plurality of bolts. Thereby, the stator 12 is clamped in the radial direction by the first split body 54 and the second split body 56, and the fixture body 52 and the stator 12 are arranged concentrically. It should be noted that a configuration in which the fixture body 52 is not divided into the first split body 54 and the second split body 56 may also be adopted. In this case, when the stator 12 is attached to the fixture body 52, the stator 12 is inserted axially into the cylindrical fixture body 52.

[0039] On an axial end face of the fixture body 52, a fitting recess 62 for fitting the terminal positioning portion 60 is formed in the first split body 54. The fitting recess 62 is formed at the circumferential center portion of the first split body 54 and is arc-shaped when viewed axially of the fixture body 52. The portion of the first split body 54 where the fitting recess 62 is formed is recessed axially of the fixture body 52. The fitting recess 62 and the terminal pressing portion 70 together constitute the terminal positioning portion 60.

[0040] The terminal pressing portion 70 is formed, for example, of metal into a long plate shape. The terminal pressing portion 70 is arc-shaped when viewed in the plate thickness direction and is configured to be capable of fitting axially (i.e., axially of the stator 12) of the fixture body 52 relative to the fitting recess 62. The thickness dimension of the terminal pressing portion 70 is set to be approximately the same as the depth dimension of the fitting recess 62. A plurality (here, two) of bolt insertion holes 72 are formed side by side in the long dimension direction of the terminal pressing portion 70. These bolt insertion holes 72 are formed with steps. A plurality (here, two) of bolts 76 inserted into these bolt insertion holes 72 are screwed into a plurality (here, two) of internal threaded holes 64 formed in the bottom surface of the fitting recess 62, whereby the terminal pressing portion 70 is fastened and fixed to the fixture body 52.

[0041] As Figure 4 、 Figure 6 And Figure 7 As shown, a plurality (here, three) of positioning recesses 66 are respectively formed in the bottom surface of the fitting recess 62. The plurality of positioning recesses 66 are recessed axially of the fixture body 52 and extend along the radial direction of the fixture body 52, and are arranged at equal intervals in the circumferential direction of the fixture body 52. When the stator 12 is attached to the fixture body 52, a plurality of terminal portions 24 are inserted into the three positioning recesses 66.

[0042] As Figure 6As shown, at positions on the lower surface of the terminal pressing portion 70 that face the plurality of positioning recesses 66, a plurality (here, three) of positioning recesses 74 are respectively formed. The plurality of positioning recesses 66 and the plurality of positioning recesses 74 correspond to the "recesses" in the present disclosure. When the terminal pressing portion 70 is fitted into the fitting recess 62, the plurality of terminal portions 24 are inserted axially with respect to the plurality of positioning recesses 74. In a state where the terminal pressing portion 70 is fastened and fixed to the jig body 52, the plurality of terminal portions 24 are sandwiched between the terminal pressing portion 70 and the jig body 52 and are in contact with both. In this state, the plurality of terminal portions 24 are restricted from axial and circumferential displacement with respect to the jig body 52 (i.e., the stator 12) by the plurality of positioning recesses 66 and the plurality of positioning recesses 74. However, the depth dimensions of the plurality of positioning recesses 66 and the plurality of positioning recesses 74 are set with a gap such that the plurality of terminal portions 24 can be slightly displaced axially and circumferentially with respect to the jig body 52. This gap is changed according to the required positional accuracy of the plurality of terminal portions 24.

[0043] In the first split body 54 of the jig body 52, a plurality (here, 3) of pin insertion holes 68 that communicate with the plurality of positioning recesses 66 are formed. The plurality of pin insertion holes 68 penetrate the first split body 54 in the axial direction of the jig body 52 and are arranged in the circumferential direction of the jig body 52. When the terminal positioning jig 50 to which the stator 12 is attached is attached to the lower die 42 of the molding die 40, the core portion 42B provided on the lower die 42 is inserted into the inside of the stator 12, and the plurality of positioning pins 42C provided on the lower die 42 are inserted into the plurality of pin insertion holes 68, and the terminal positioning jig 50 is placed on the base portion 42A of the lower die 42. The top ends of the plurality of positioning pins 42C are inserted into the respective bolt holes 26 of the plurality of terminal portions 24. Thereby, the plurality of terminal portions 24 can be accurately positioned with respect to the lower die 42. In this state, it is configured to perform resin molding by the stator molding device 10. When the resin molding is completed, the terminal positioning jig 50 and the stator 12 are removed from the lower die 42 together by an ejector pin (not shown) provided on the lower die 42.

[0044] Next, the operation and effects of the present embodiment will be described.

[0045] In the stator molding device 10 configured as described above, resin molding is performed on the stator 12, which includes a stator core 14, a coil 16, and a bus bar unit 18. The stator molding device 10 includes: a molding die 40 having a lower die 42 and an upper die 44; and a terminal positioning jig 50 attached to the molding die 40. The terminal positioning jig 50 has: a terminal positioning portion 60 that contacts the plurality of terminal portions 24 included in the bus bar unit 18 and positions the plurality of terminal portions 24 with respect to the molding die 40.

[0046] Thus, the terminal positioning portion 60 of the terminal positioning jig 50 attached to the molding die 40 is in direct contact with the plurality of terminal portions 24. Therefore, compared with the configuration in which the plurality of terminal portions 24 are positioned in the molding die 40 via a resin member, it is easier to ensure the positional accuracy of the plurality of terminal portions 24.

[0047] In addition, in this terminal positioning jig 50, the jig main body 52 is arranged (attached) on the radially outer side with respect to the stator 12, and the terminal pressing portion 70 is fixed to the jig main body 52 in the axial direction of the stator 12. In the terminal positioning portion 60 of the terminal positioning jig 50, the plurality of terminal portions 24 are clamped between the jig main body 52 and the terminal pressing portion 70. Therefore, the plurality of terminal portions 24 can be positioned with high precision in the axial direction of the stator 12.

[0048] In addition, the above-mentioned terminal positioning portion 60 has: a plurality of positioning recesses 66 formed in the jig main body 52; and a plurality of positioning recesses 74 formed in the terminal pressing portion 70. The plurality of terminal portions 24 are inserted into these positioning recesses 66 and 74 along the axial direction of the stator 12. Thereby, the plurality of terminal portions 24 can be positioned with high precision in the circumferential direction of the stator 12.

[0049] In addition, in the present embodiment, the terminal positioning jig 50 can be removed from the molding die 40. Therefore, for example, the stator 12 can be disassembled and assembled with respect to the terminal positioning jig 50 in a state where the terminal positioning jig 50 is removed from the molding die 40, and the workability is improved. In addition, the terminal positioning jig 50 can be processed as it is mounted on the stator 12 before and after resin molding. Therefore, for example, a heat treatment process for completely curing the molded sealing resin 28 can also be performed in a state where the plurality of terminal portions 24 are positioned by the terminal positioning jig 50.

[0050] It should be noted that, in the above embodiment, a configuration in which the terminal positioning jig 50 can be attached to / detached from the lower die 42 of the molding die 40 is adopted, but it is not limited thereto. For example, a configuration in which the jig main body 52 of the terminal positioning jig 50 is integrally formed with the lower die 42 can also be adopted.

[0051] In addition, in the above embodiment, a configuration in which a plurality of positioning recesses 66 and 74 are formed in the jig main body 52 and the terminal pressing portion 70 is adopted, but a configuration in which one or both of the plurality of positioning recesses 66 and 74 are not formed can also be adopted.

[0052] In addition, in the above embodiment, a configuration in which the terminal positioning jig 50 includes the jig main body 52 and the terminal pressing portion 70 is adopted, but the configuration of the terminal positioning jig 50 can be appropriately changed.

[0053] In addition, the present disclosure can be implemented with various modifications without departing from its gist. Moreover, the scope of rights of the present disclosure is of course not limited to the above-described embodiments.

[0054] In addition, with respect to the disclosure of Japanese Patent Application No. 2022-212375 filed on December 28, 2022, the entirety thereof is incorporated herein by reference. All documents, patent applications, and technical standards described in this specification are incorporated herein by reference in the same manner as if each individual document, patent application, and technical standard were specifically and separately described as being incorporated by reference.

Claims

1. A terminal positioning fixture is attached to a molding die for resin-molding a stator. The stator includes: a stator core; a coil wound around teeth of the stator core; and a bus bar unit having a plurality of bus bars electrically connected to the coil. The terminal positioning fixture has: A terminal positioning portion that contacts an externally connecting terminal included in the bus bar unit and positions the externally connecting terminal relative to the molding die.

2. The terminal positioning fixture according to claim 1, comprising: A fixture body disposed radially outside the stator; and A terminal pressing portion fixed to the fixture body in the axial direction of the stator, wherein the terminal positioning portion is configured to sandwich the externally connecting terminal between the fixture body and the terminal pressing portion.

3. The terminal positioning fixture according to claim 1 or 2, wherein the terminal positioning portion has a recess formed in at least one of the fixture body and the terminal pressing portion, into which the externally connecting terminal is inserted along the axial direction of the stator.

4. The terminal positioning fixture according to claim 1 or 2, wherein the terminal positioning fixture is detachable from the molding die.

5. A stator molding apparatus for resin-molding a stator, the stator including: a stator core; a coil wound around teeth of the stator core; and a bus bar unit in which a plurality of bus bars electrically connected to the coil are integrally formed of resin. The stator molding apparatus includes: A molding die; and The terminal positioning fixture according to claim 1 or 2 attached to the molding die.

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