Resolver stator winding cutting structure and cutting method

Abstract

To bind and cut stator windings on a resolver which performs ultrasonic junction of an end wire of the stator windings to a terminal pin.SOLUTION: A cutting structure and a cutting method for stator windings of a resolver according to the invention comprises a first ring-shaped insulation cap (13) which is provided on one surface (12) of a ring-shaped stator (11) and has a terminal pin holding part (10) having a plurality of terminal pins (2), a second ring-shaped insulation cap (17) which is provided on the other surface (16) of the ring-shaped stator (11), a flat surface (15) and pins (2A) provided on each of the terminal pins (2), and a resin pin (21) which is integrally formed with the terminal pin holding part (10) at a downstream side (K) of the terminal pin (2) and has an edge (22). An end wire (19A) of a stator winding (19) is ultrasonically joined to the flat surface (15). The end wire (19A) of the stator winding (19) is bound about the resin pin (21) and is cut at the edge (22).SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a resolver stator winding cutting structure and cutting method, and in particular to a new improvement for ultrasonically joining a stator winding to a flat portion of a terminal pin, winding an end wire of the stator winding around a resin pin, and cutting the end wire with the edge of the resin pin. [Background technology]

[0002] As a terminal pin in this type of resolver that has been used conventionally, for example, the configuration shown in FIG. 5 (disclosed in FIG. 2 of Patent Document 1) can be disclosed. The terminal pin 2 has a first corner 4 of the press burr 4a left at the upper terminal upper part 6A, and a second corner 4A of a curved surface 4Aa without a press burr 4a at the lower coil winding part 6B, with the aim of smooth coil winding and coil cutting. That is, the press burr 4a remains at the first corner 4 of the terminal upper part 6A of the terminal pin 2, and the second corner 4A of the coil winding part 6B is a curved surface 4Aa with the press burr 4a crushed, so that the coil 5 can be smoothly wound around the coil winding part 6B, and the coil 5 after winding can be cut off by the press burr 4a of the terminal upper part 6A.

[0003] That is, in the conventional configuration shown in FIG. 5, each second corner 4A of the coil winding portion 6B of the terminal pin 2 made of a square metal is finished into a curved surface 4Aa, and the stator winding is wrapped around it, and then the wrapped stator winding is welded to the coil winding portion 6B by TIG welding. Furthermore, the end of the stator winding wound around coil winding portion 6B is cut off by press burr 4a at first corner portion 4 of terminal upper portion 6A, completing a series of steps for connecting the stator winding to terminal pin 2. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2007-139688 A Summary of the Invention [Problem to be solved by the invention]

[0005] The terminal pins in the conventional resolver are configured as described above, and therefore have the following problems. Conventional terminal pins are metal products formed by pressing, and therefore the pressed terminal pins must be mounted in a die and then insert-molded into the terminal pin holding portion, making it difficult to reduce costs. In addition, post-processing of the metal terminal pins is required, which is an obstacle to the processing of the terminal pins. A recent technological trend in resolvers is to connect the stator winding to the terminal pin by ultrasonic bonding, which was difficult to achieve with terminal pin 2 in Figure 5. Furthermore, ultrasonic bonding requires the use of an ultrasonic horn, which requires a flat welding space on the terminal pin, posing a major problem in that the stator winding cannot be tied off and cut.

[0006] The present invention has been made to solve the above-mentioned problems, and in particular provides a configuration and method in which the end wire of the stator winding is ultrasonically joined to the flat portion of the terminal pin, the end wire of the stator winding is wrapped around a resin pin, and the end wire is cut by the edge of the resin pin. [Means for solving the problem]

[0007] The resolver stator winding cutting structure according to the present invention comprises a ring-shaped stator having a plurality of protruding magnetic poles that protrude inward at a predetermined angular interval and around which a stator winding is wound, a first ring-shaped insulating cap provided on one surface of the ring-shaped stator and having a terminal pin holding portion provided with a plurality of terminal pins, a second ring-shaped insulating cap provided on the other surface of the ring-shaped stator, flat surfaces and pins provided on each of the terminal pins, and a terminal pin holding portion formed integrally with the terminal pin holding portion on the downstream side of the terminal pins, Consists of a triangular or rectangular prism. a resin pin having an edge, the stator winding being ultrasonically bonded to the flat surface, and an end wire of the stator winding being wrapped around the resin pin; By being pulleda first width W1 perpendicular to the longitudinal direction of the flat surface and a second width W2 perpendicular to the longitudinal direction of the terminal pins satisfy a relationship W1≧W2; and a method for cutting a stator winding of a resolver according to the present invention includes a ring-shaped stator having a plurality of protruding magnetic poles that protrude inward at predetermined angular intervals and around which the stator winding is wound, a first ring-shaped insulating cap provided on one surface of the ring-shaped stator and having a terminal pin holding portion provided with a plurality of terminal pins, a second ring-shaped insulating cap provided on the other surface of the ring-shaped stator, flat surfaces and pins provided on each of the terminal pins, and a terminal pin holding portion formed integrally with the terminal pin holding portion on the downstream side of the terminal pins, Consists of a triangular or rectangular prism. a resin pin having an edge, the stator winding is ultrasonically bonded to the flat surface, and an end wire of the stator winding is wrapped around the resin pin; By being pulled The terminal pin is cut at the edge, and the terminal pin holding portion has a plurality of positioning pins formed integrally with the terminal pin holding portion on the upstream side of the terminal pin, and the stator winding wound around the protruding magnetic pole is wound on the flat surface after being tied or hooked by the positioning pins, and a first width W1 perpendicular to the longitudinal direction of the flat surface and a second width W2 perpendicular to the longitudinal direction of the terminal pin have a relationship of W1 ≧ W2. Effect of the Invention

[0008] Since the resolver stator winding cutting structure and cutting method according to the present invention are configured as described above, the following effects can be obtained. That is, the rotor comprises an annular stator having a plurality of protruding magnetic poles that protrude inward at a predetermined angular interval and around which a stator winding is wound; a first annular insulating cap provided on one surface of the annular stator and having a terminal pin holding portion provided with a plurality of terminal pins; a second annular insulating cap provided on the other surface of the annular stator; flat surfaces and pins provided on each of the terminal pins; and a terminal pin holding portion formed integrally with the terminal pin holding portion on the downstream side of the terminal pins. Consists of a triangular or rectangular prism. Since a resin pin having an edge is used, the stator winding is ultrasonically bonded to the flat surface, and the end wire of the stator winding is wrapped around the resin pin, By being pulled, By cutting at the edge, the terminal pin holding portion is ultrasonically joined, i.e., even though the terminal pin has a flat portion for ultrasonic joining, the end wire of the stator winding after ultrasonic joining is wound around the resin pin, and then the needle of the automatic winding machine (not shown) is used. Pull This operation allows the end wire to be cut by the edge of the resin pin, which can greatly contribute to improving the production efficiency of resolvers. In addition, the stator winding has a plurality of positioning pins formed integrally with the terminal pin holding portion on the upstream side of the terminal pin, and the stator winding wound around the protruding magnetic pole is wrapped or hooked by the positioning pins and then sent to the flat surface, thereby positioning and fixing the end wire. Furthermore, since the first width W1 perpendicular to the longitudinal direction of the flat surface and the second width W2 perpendicular to the longitudinal direction of the terminal pin have a relationship of W1≧W2, the flat portion, which is the location for ultrasonic bonding, can be formed long within a limited space, making bonding easier. [Brief description of the drawings]

[0009] [Figure 1] 1 is a perspective view of a main portion showing a stator winding cutting structure of a resolver according to an embodiment of the present invention; [Diagram 2] FIG. 2 is an enlarged perspective view of a portion of the protruding magnetic pole of FIG. [Diagram 3] FIG. 2 is an enlarged perspective view of the terminal pin of FIG. [Figure 4] FIG. 2 is an enlarged perspective view showing the resin pin of FIG. [Diagram 5] FIG. 1 is a perspective view showing a conventional terminal pin. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention provides a resolver stator winding cutting structure and method in which the stator winding is ultrasonically joined (i.e., welded or fused) to the flat portion of a terminal pin, the end wire of the stator winding is wrapped around a resin pin, and the end wire is cut with the edge of the resin pin. EXAMPLES

[0011] Hereinafter, preferred embodiments of a resolver stator winding cutting structure and cutting method will be described with reference to the drawings. In addition, parts that are the same as or equivalent to those in the conventional example are denoted by the same reference numerals. FIG. 1 shows the peripheral area of ​​a terminal pin holding portion 10 which is a main part of a resolver according to the present invention. The terminal pin holding portion 10 has a plurality of terminal pins 2 and is provided on one surface 12 of an annular stator 11. The terminal pin holding portion 10 is integrally molded with a part of the peripheral edge 14 of a first ring-shaped insulating cap 13 provided on the one surface 12, and a flat surface 15 is formed at the central position of each terminal pin 2.

[0012] A second annular insulating cap 17 is provided on the other surface 16, which is the opposite surface to the one surface 12 of the annular stator 11, to form a pair with the first annular insulating cap 13, and the annular stator 11 is sandwiched between the annular insulating caps 13 and 17. As shown in FIG. 2, each tongue 13A, 17A of each annular insulating cap 13, 17 holds a protruding magnetic pole 18, and a stator winding 19 consisting of an excitation winding and an output winding is wound around each tongue 13A, 17A so as to simultaneously bind the outer periphery of each annular insulating cap 13, 17 and the protruding magnetic pole 18. Thus, although the annular insulating caps 13, 17 are fixed at the protruding magnetic poles 18, they may be formed by a known snap-fit ​​structure (not shown) or by insert molding to integrate the entire caps.

[0013] When viewed from the direction of movement of the stator winding 19, the terminal pin holding portion 10 is provided with a plurality of positioning pins 20 on the upstream side J of the terminal pin 2, and a plurality of resin pins 21 having edges 22 and consisting of triangular or rectangular prisms are provided integrally with the terminal pin holding portion 10 on the downstream side K of the terminal pin 2. After the stator winding 19 is wound around the positioning pin 20, the end wire 19A is ultrasonically bonded to the flat surface 15, and the remaining end wire 19A is wound around the resin pin 21. The end wire 19A is then wound around the resin pin 21 by the needle of an automatic winding machine (not shown). Pull by operation (See the white arrow in Figure 1) By , a resin pin 21 made of a triangular prism or a square prism It is cut at edge 22 .

[0014] As shown in Figure 3, each terminal pin 2 is provided with a pair of pins 2A when viewed along the longitudinal direction P of a flat surface 15 having a sufficiently large area, and a first width W1 in a direction perpendicular to the longitudinal direction P of the flat surface 15 is shown in the figure such that W1 ≧ W2 is satisfied with respect to a second width W2 in a direction perpendicular to the longitudinal direction P of the pin 2A. The resin pin 21 shown in FIG. 4 is integrally formed with the terminal pin holding portion 10 made of insulating resin. Therefore, compared with conventional metal terminal pins, no electrical considerations are required. Even if the needle of an automatic winding machine (not shown) is operated in three dimensions (X, Y, Z) to perform winding, hooking and cutting operations, a high yield can be obtained. [Industrial Applicability]

[0015] The resolver stator winding cutting structure and cutting method according to the present invention provides a terminal pin with a flat surface on only one of a pair of first and second annular insulating caps, the first annular insulating cap, and ultrasonically joins the end wire of the stator winding to the terminal pin using this flat surface. The end wire of the stator winding is then wrapped around a resin pin and cut using its edge. Therefore, while having a flat surface for ultrasonic joining, the end wire can be wrapped around the resin pin and cut using the edge of the resin pin, significantly improving the efficiency of resolver manufacturing. [Explanation of symbols]

[0016] 2 Terminal Pin 2A pin 10 Terminal pin holder 11 Ring-shaped stator 12 one side 13 First ring-shaped insulating cap 13A tongue piece 14 Periphery 15 flat surface 16 Other side 17 Second ring-shaped insulating cap 17A tongue piece 18 protruding magnetic pole 19 Stator Winding 19A end wire 20 Positioning pin 21 Resin pin 22 Edge J upstream side K downstream side P Longitudinal direction W1 1st width W2 Second width

Claims

1. the annular stator (11) having a plurality of protruding magnetic poles (18) protruding inward at a predetermined angular interval and around which a stator winding (19) is wound; a first annular insulating cap (13) provided on one surface (12) of the annular stator (11) and having a terminal pin holding portion (10) on which a plurality of terminal pins (2) are provided; a second annular insulating cap (17) provided on the other surface (16) of the annular stator (11); flat surfaces (15) and pins (2A) provided on each of the terminal pins (2); and a resin pin (21) formed integrally with the terminal pin holding portion (10) on the downstream side (K) of the terminal pins (2), which is made of a triangular or quadrangular prism and has an edge (22), The stator winding (19) is ultrasonically joined to the flat surface (15), and an end wire (19A) of the stator winding (19) is hooked onto the resin pin (21) and cut by the edge (22) when pulled.

2. 2. The resolver stator winding cutting structure according to claim 1, further comprising a plurality of positioning pins (20) formed integrally with the terminal pin holding portion (10) on the upstream side (J) of the terminal pin (2), and the stator winding (19) wound around the protruding magnetic pole (18) is configured to be wound or hooked by the positioning pins (20) and then fed to the flat surface (15).

3. 3. The resolver stator winding cutting structure according to claim 1, wherein a first width (W1) perpendicular to the longitudinal direction (P) of the flat surface (15) and a second width (W2) perpendicular to the longitudinal direction (P) of the terminal pin (2) satisfy a relationship of W1 ≧ W2.

4. a first annular insulating cap (13) provided on one surface (12) of the annular stator (11) and having a terminal pin holding portion (10) provided with a plurality of terminal pins (2); a second annular insulating cap (17) provided on the other surface (16) of the annular stator (11); flat surfaces (15) and pins (2A) provided on each of the terminal pins (2); and a resin pin (21) formed integrally with the terminal pin holding portion (10) on the downstream side (K) of the terminal pins (2), which is made of a triangular or quadrangular prism and has an edge (22), the stator winding (19) is ultrasonically joined to the flat surface (15), and an end wire (19A) of the stator winding (19) is hooked onto the resin pin (21) and pulled to be cut at the edge (22).

5. 5. The resolver stator winding cutting method according to claim 4, further comprising a plurality of positioning pins (20) formed integrally with the terminal pin holding portion (10) on the upstream side (J) of the terminal pin (2), and the stator winding (19) wound around the protruding magnetic pole (18) is wound onto the flat surface (15) after being tied or hooked by the positioning pins (20).

6. 6. The resolver stator winding cutting method according to claim 4 or 5, characterized in that a first width (W1) perpendicular to the longitudinal direction (P) of the flat surface (15) and a second width (W2) perpendicular to the longitudinal direction (P) of the terminal pin (2) satisfy a relationship of W1 ≧ W2.

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