Method for manufacturing a stator

Abstract

To provide a method for manufacturing a stator which can easily manufacture a stator mounting an electronic component on a circuit board.SOLUTION: A method for manufacturing a stator which is arranged so as to face a rotor rotating about a central axis includes: 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 of 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 stator cover; a third step of heating and curing the thermosetting resin, and thereby fixing the stator cover, the stator core and the coil onto the substrate; a fourth step of mounting the electronic component onto the substrate, and connecting the electronic component to the circuit pattern; and a fifth step of cutting a mounting region where the stator cover of the substrate, the stator core, the coil and the electronic component are mounted from a non-mounting region around the substrate mounting region.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a stator disposed opposite to a rotor that rotates about a central axis.

Background Art

[0002] Conventionally, a motor having a stator disposed opposite to a rotor that rotates about a central axis is known.

[0003] For example, Patent Document 1 discloses an axial gap type electric motor having a stator integrally formed of a mold resin in a state where nine core members, in which windings are wound around an insulator covering the teeth portion of a stator core, are connected in a ring shape. In the stator of Patent Document 1, a shaft insertion hole into which a shaft is inserted, a pair of bearing accommodation holes that are continuously formed in the shaft insertion hole and each accommodate a bearing, a substrate arrangement step portion on which a circuit board is arranged, and a pair of lid fitting step portions into which a bracket lid is respectively fitted are integrally formed of a mold resin.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in Patent Document 1, there is no description regarding electronic components mounted on the circuit board, and there is also no specific description regarding the method for manufacturing the stator. Therefore, there is room for improvement in easily manufacturing a stator on which electronic components are mounted on the circuit board.

[0006] An object of the present 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.

Means for Solving the Problems

[0007] The manufacturing method of the stator according to the present invention is a manufacturing method of a stator disposed opposite to a rotor that rotates about a central axis, and an annular stator cover is provided on an insulating substrate having a circuit pattern. Arrangement Then, inside the stator cover of the substrate A member different from the stator cover a stator core is Arrangement provided, and a coil is Arrangement provided around the stator core. A first step of connecting the coil to the circuit pattern, a second step of injecting a liquid thermosetting resin inside the stator cover, and heating and curing the thermosetting resin to fix the stator cover, the stator core, and the coil on the substrate To mount the stator cover, the stator core, and the coil on the substrate A third step of doing so, a fourth step of mounting electronic components on the substrate and connecting them to the circuit pattern, and a fifth step of cutting the mounting area on 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.

Advantages of the Invention

[0008] According to the present invention, a stator for mounting electronic components on a circuit board can be easily manufactured.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0010] Hereinafter, with reference to the drawings, an axial motor and a stator including the stator according to an embodiment of the present invention will be described. Note that the scope of the present invention is not limited to the following embodiments and can be arbitrarily changed within the scope of the technical idea of the present invention. Also, in the following drawings, in order to make each configuration easier to understand, the scale, number, etc. of each structure may be different from those in the actual structure.

[0011] <Configuration of Axial Motor> The configuration of the axial motor 100 including the stator 2 according to an embodiment of the present invention will be described in detail with reference to FIGS. 1 and 2.

[0012] The axial motor 100 has a rotor 1 that rotates, a stator 2 for rotating the rotor 1, and a bearing 15.

[0013] The rotor 1 includes a shaft 11, a yoke 12, a magnet 13, a yoke 14, and an encoder disk 16.

[0014] The shaft 11 passes through the yoke 12, the encoder disk 16, the stator coil assembly 21, and the front cover 23, and is a rotating shaft (central axis) for relatively rotating the rotor 1 with respect to the stator 2.

[0015] The yoke 12 is disposed opposite to one surface (the upper surface in FIG. 2) of the stator coil assembly 21 in the rotational axis direction, and is attached to the shaft 11.

[0016] The magnets 13 are arranged along the circumferential direction on the opposing surface of the yoke 12 to the stator coil assembly 21, and are arranged along the circumferential direction on the opposing surface of the yoke 14 to the stator coil assembly 21.

[0017] The yoke 14 is disposed opposite to the other surface (the lower surface in FIG. 2) of the stator coil assembly 21 in the rotational axis direction, and is attached to the shaft 11.

[0018] The encoder disk 16 is provided on the opposing surface of the stator coil assembly 21 to the yoke 14.

[0019] The stator 2 is disposed opposite to the rotor 1 in the rotational axis direction, and includes a stator coil assembly 21, a front cover 23, and a rear cover 24.

[0020] The stator coil assembly 21 is provided between the yoke 12 and the yoke 14. The stator coil assembly 21 is disposed opposite to the rotor 1 in the central axis direction. Details of the configuration of the stator coil assembly 21 will be described later.

[0021] The front cover 23 houses the yoke 12 and fastens and fixes the stator coil assembly 21 with the front bolts 25.

[0022] The rear cover 24 houses the yoke 14 and fastens and fixes the stator coil assembly 21 with the rear bolts 26.

[0023] The bearing 15 is provided on the facing surface side with the yoke 12 of the stator coil assembly 21 and on the facing surface side with the yoke 14, and rotatably supports the shaft 11.

[0024] <Configuration of the stator coil assembly> The configuration of the stator coil assembly 21 of the stator 2 according to the embodiment of the present invention will be described in detail with reference to FIGS. 2 to 4.

[0025] 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 set 217, and a bearing holder 219.

[0026] The stator cover 211 is annular. The stator cover 211 is provided with concave groove portions 211A at intervals of 90 degrees in the circumferential direction. The stator cover 211 is provided with fastening holes 211B into which a front bolt 25 for fastening the front cover 23 and a rear bolt 26 for fastening the rear cover 24 are press-fitted between the concave groove portions 211A.

[0027] The substrate 212 is formed of an insulating material and includes a connecting portion 212A and a main substrate 212C. A conductive circuit pattern (not shown) is formed on the main substrate 212C by printing, and the stator core 213, coil 214, magnetic sensor 215, encoder sensor IC 216, power signal terminal set 217, and bearing holder 219 connected to this circuit pattern are mounted thereon.

[0028] The stator core 213 is radially mounted around the shaft 11 inside the stator cover 211 of the main substrate 212C. A plurality of stator cores 213 are mounted on the main substrate 212C at intervals along the circumferential direction.

[0029] The coil 214 is mounted around the stator core 213 and is connected to the circuit pattern of the main board 212C. Note that the stator core 213 and the coil 214 are not limited to the numbers shown in FIG. 3, and any number can be used as long as one or more are provided.

[0030] The magnetic sensor 215 is mounted at a position farther from the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21 of the main board 212C. The magnetic sensor 215 is surface-mounted on the main board 212C by 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 board 212C.

[0031] The encoder sensor IC 216 is mounted at a position closer to the shaft 11 (central axis) than the stator core 213 in the radial direction of the stator 2 and the stator coil assembly 21 of the main board 212C. The encoder sensor IC 216 is surface-mounted on the main board 212C by SMT. The encoder sensor IC 216 detects the position of the rotor 1 by reading the encoder disk 16 and outputs an electrical signal corresponding to the detection result to the connector 217A via the circuit pattern of the main board 212C.

[0032] The power signal terminal set 217 is composed of a connector 217A and a power connector 217B. The power signal terminal set 217 is surface-mounted on the main board 212C by SMT.

[0033] The connector 217A is mounted on the main board 212C. Signal terminals (not shown) of the connector 217A are connected to the circuit pattern of the main board 212C, and it is connected to the magnetic sensor 215 and the encoder sensor IC 216 via the circuit pattern of the main board 212C. The connector 217A is fitted with a mating connector (not shown) to output externally the electrical signal output from the magnetic sensor 215 or the encoder sensor IC 216.

[0034] The power connector 217B is mounted on the main board 212C. The power connector 217B has power terminals (not shown) connected to the circuit pattern of the main board 212C and is connected to the coil 214 via the circuit pattern of the main board 212C. The power connector 217B mates with a mating connector (not shown) to supply power to the coil 214.

[0035] The bearing holder 219 is attached to the main board 212C. The bearing holder 219 has the shaft 11 inserted therethrough and holds the bearing 15.

[0036] <Manufacturing method of stator> A method for manufacturing the stator 2 according to an embodiment of the present invention will be described in detail with reference to FIGS. 2 and 5 to 10. Note that in FIG. 7, the description of the tooling frame board 212B is omitted.

[0037] First, a board 212 shown in FIG. 6 having a connecting portion 212A for connecting the main board 212C and the tooling frame board 212B at the slit portion 212D is prepared.

[0038] Here, the board 212 is composed of the connecting portion 212A, the tooling frame board 212B, and the main board 212C.

[0039] The main board 212C has a fitting hole 212F that penetrates in the thickness direction of the board 212 and is for fitting the stator core 213. The fitting holes 212F are provided radially around the central axis through which the shaft 11 is inserted. A slit portion 212D that penetrates in the thickness direction of the board 212 is provided between the tooling frame board 212B and the main board 212C.

[0040] Next, as shown in FIG. 6, an annular stator cover 211 is placed on the insulating main board 212C having a circuit pattern. ArrangementThen, inside the stator cover 211 of the main board 212C A member different from the stator cover 211 place the stator core 213 Arrangement Then, place the coil 214 around the stator core 213 Arrangement Then, connect the coil 214 to the circuit pattern of the main board 212C (first step) (S1). As a result, the state shown in FIG. 7 is obtained.

[0041] Also, in the first step, engage the connecting portion 212A with the concave groove portion 211A provided in the stator cover 211, and insert the stator cover 211 into the slit portion 212D to Arrangement attach the stator cover 211 to the main board 212C. As a result, the stator cover 211 can be easily positioned on the board 212.

[0042] Furthermore, in the first step, fit the stator core 213 into the fitting hole 212F to Arrangement attach the stator core 213 to the main board 212C. As a result, the stator core 213 can be easily positioned with respect to the main board 212C.

[0043] Next, as shown in FIG. 8, inject a liquid thermosetting resin into the gap between the stator cover 211 and the coil 214 inside the stator cover 211 (second step) (S2).

[0044] Next, heat and cure the thermosetting resin to form the resin portion 218, and fix the stator cover 211, the stator core 213, and the coil 214 on the main board 212C To mount the stator cover 211, the stator core 213, and the coil 214 on the main substrate 212C (third step) (S3). Before mounting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 on the main board 212C, by heating the thermosetting resin to form the resin portion 218, it is possible to prevent damage to the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 due to heating.

[0045] Next, as shown in FIG. 9, with the up and down reversed with respect to the state shown in FIG. 8, a magnetic sensor 215, an encoder sensor IC 216, and a power signal terminal set 217, which are electronic components, are surface-mounted on the main board 212C and connected to the circuit pattern of the main board 212C (fourth step) (S4). At this time, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main board 212C by an automatic machine such as a chip mounter. Also, the touring frame board 212B arranged around the main board 212C is supported by the automatic machine when being conveyed inside the automatic machine. By providing the touring frame board 212B, it is possible to easily position the board 212 on the belt conveyor inside the automatic machine.

[0046] Next, as shown in FIG. 10, by cutting the connecting portion 212A, the main board 212C, which is the mounting area on which the stator cover 211, the stator core 213, the coil 214, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted, is cut from the touring frame board 212B, which is the non-mounting area around the main board 212C (fifth step) (S5). In this way, by cutting the connecting portion 212A, the main board 212C and the touring frame board 212B can be cut, so the main board 212C and the touring frame board 212B can be easily cut.

[0047] By cutting the connecting portion 212A, a burr 212E remains on the touring frame board 212B, and a burr also remains on the cross-section 212G of the connecting portion 212A of the stator coil assembly 21. Furthermore, the cross-section 212G becomes a fracture surface.

[0048] Using the stator coil assembly 21 manufactured by the above manufacturing method, the stator 2 is manufactured so as to have the arrangement shown in FIG. 2.

[0049] Thus, according to this embodiment, after the third step of fixing the stator cover 211, the stator core 213, and the coil 214 on the main board 212C by heating and curing the thermosetting resin, the fourth step of mounting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 on the main board 212C and connecting them to the circuit pattern is performed. By doing so, it is possible to prevent the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 from being heated at a high temperature due to the heating during the curing of the thermosetting resin, and the stator coil assembly 21 in which the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted on the main board 212C can be easily manufactured.

[0050] Further, according to this embodiment, in the fourth step, by surface-mounting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 on the main board 212C, the work of connecting the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 to the circuit pattern of the main board 212C can be automated by an automated SMT production line, the man-hours can be significantly reduced, and the manufacturing cost can be reduced.

[0051] The above-described embodiments should be considered as illustrative in all respects and not restrictive. The scope of the present invention is shown not by the above-described embodiments but by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

[0052] Specifically, in the above embodiment, the stator coil assembly 21 is provided in the axial flux motor 100, but the present invention is not limited to this, and the stator coil assembly 21 may be provided in a motor other than the axial flux motor.

[0053] Also, in the above embodiment, the stator core 213 is provided, but the present invention is not limited to this, and the stator core 213 may not be provided.

[0054] Also, in the above embodiment, the electronic components of the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main board 212C. However, the present invention is not limited to this, and the electronic components may be mounted on the main board by a mounting method other than surface mounting, such as through-hole mounting.

[0055] Also, in the above embodiment, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are surface-mounted on the main board 212C by an automatic machine. However, the present invention is not limited to this, and the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 may be mounted on the main board 212C manually.

[0056] Also, in the above embodiment, the magnetic sensor 215, the encoder sensor IC 216, and the power signal terminal set 217 are mounted on the main board 212C as electronic components. However, the present invention is not limited to this, and any electronic components can be mounted on the main board as required.

[0057] Also, in the above embodiment, in the radial direction of the stator 2 and the stator coil assembly 21, the magnetic sensor 215 is mounted at a position farther from the shaft 11 (central axis) than the stator core 213, and the encoder sensor IC 216 is mounted at a position closer to the shaft 11 (central axis) than the stator core 213. However, the present invention is not limited to this, and the magnetic sensor and the encoder can be mounted at any position on the main board.

Explanation of Reference Numerals

[0058] 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 Concave groove part 211B Fastening hole 212 Substrate 212A Connecting part 212B Touring frame substrate 212C Main substrate 212D Slit part 212E Burr 212F Fitting hole 212G Cross section 213 Stator core 214 Coil 215 Magnetic sensor 216 Encoder 217 Power signal terminal set 217A Connector 217B Power connector 218 Resin part 219 Bearing holder

Claims

1. A method for manufacturing a stator disposed opposite to a rotor that rotates about a central axis, comprising: a first step of disposing an annular stator cover on an insulating substrate having a circuit pattern, disposing a stator core, which is a member different from the stator cover, inside the stator cover on the substrate, disposing a coil around the stator core, and connecting the coil to the circuit pattern; a second step of injecting a liquid thermosetting resin inside the stator cover; a third step of heating and curing the thermosetting resin to fix the stator cover, the stator core, and the coil on the substrate, and mounting the stator cover, the stator core, and the coil on the substrate; a fourth step of mounting electronic components on the substrate and connecting them to the circuit pattern; a fifth step of cutting a mounting area on the substrate where the stator cover, the stator core, the coil, and the electronic components are mounted from a non-mounting area around the mounting area of the substrate; A method for manufacturing a stator, characterized by comprising the above steps.

2. The fourth step is surface-mounting the electronic components on the substrate. The method for manufacturing a stator according to claim 1, characterized by the above.

3. The method further comprises a step of preparing a substrate having a connecting portion that connects the mounting area and the non-mounting area in a slit portion that penetrates in the plate thickness direction provided between the mounting area and the non-mounting area of the substrate. The method for manufacturing a stator according to claim 1 or claim 2, characterized by the above.

4. The first step is placing the stator cover on the substrate by engaging the connecting portion with a concave groove provided in the stator cover and inserting the stator cover into the slit portion. The method for manufacturing a stator according to claim 3, characterized by the above.

5. The fifth step is cutting the mounting area from the non-mounting area by cutting the connecting portion. The method for manufacturing a stator according to claim 3 or claim 4, characterized by the above.

6. The fourth step is mounting a connector having a power terminal and a signal terminal as the electronic components on the substrate and connecting the power terminal and the signal terminal to the circuit pattern. The method for manufacturing a stator according to any one of claims 1 to 5, characterized by the above.

7. The fourth step is Mount a sensor for detecting the position of the rotor as the electronic component on the substrate, and connect the terminal portion of the sensor to the circuit pattern. The method for manufacturing a stator according to any one of claims 1 to 6, characterized in that.

8. The first step is, The stator core is arranged on the substrate by fitting the stator core into a fitting hole penetrating in the plate thickness direction provided in the substrate. The method for manufacturing a stator according to any one of claims 1 to 7, characterized in that.

9. The stator is, It is arranged to face the rotor in the central axis direction. The method for manufacturing a stator according to any one of claims 1 to 8, characterized in that.

10. The fourth step is, Mount the electronic component at a position closer to or farther from the central axis than the stator core in the radial direction of the stator. The method for manufacturing a stator according to any one of claims 1 to 9, characterized in that.

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