Stator assembly

Abstract

[Problem] To provide a stator assembly capable of simplifying the configuration of a terminal block and facilitating reduction in size of the terminal block and space saving. [Solution] A stator assembly 100 is provided with a stator stack 110, first through-holes 111a that are provided in the stator stack 110, an insulator 150 that covers the stator stack 110, and a terminal block 200 that is coupled to the insulator 150. The terminal block 200 has second through-holes 250 that penetrate in the axial direction of the stator stack 110. The second through-holes 250 and the corresponding first through-holes 111a are arranged in a mutually connected configuration. The size of the first through-holes 111a is smaller than the size of the second through-holes 250.

Description

stator assembly

[0001] The present invention relates to a stator assembly for an angle sensor such as a resolver, and more particularly to a technique for simplifying the configuration of a terminal block.

[0002] Resolvers have been known as a means for detecting the rotation angle of rotating electrical machines such as motors and generators. A resolver includes a stator assembly in which an insulator is insert-molded into a stator stack. A terminal block is molded integrally with the insulator, and stack retainer pins are provided in the mold to press down on the stator stack from above and below to prevent the stator core of the stator stack from being deformed by the molding pressure of the terminal block during injection molding. As a result, through holes are formed in the terminal block after injection molding, where the stack retainer pins were removed.

[0003] Meanwhile, terminals are insert-molded into the terminal block. The conductor wires drawn from the coil are wound around the terminals and fixed there by welding or soldering. To prevent the conductor wires from being cut due to temperature changes, vibrations, etc., slack is formed in the conductor wires drawn from the coil. Patent Document 1 discloses a technology in which a loosening pin insertion hole 43 is provided in the terminal block. In this technology, a loosening pin is protruded from the loosening pin insertion hole 43, the conductor wire is hooked onto the loosening pin and wound around the terminal to fix it, and then the loosening pin is removed to provide slack in the conductor wire.

[0004] Japanese Patent Application Laid-Open No. 2019-146367

[0005] In Patent Document 1, a through hole is formed in a resin member, for example, in the terminal block, next to the loosening pin insertion hole 43, where the stack retainer pin was removed. This makes the configuration of the terminal block complicated, posing a challenge to miniaturizing and saving space in the terminal block.

[0006] The present invention has been made in consideration of the above circumstances, and aims to provide a stator assembly that can simplify the configuration of components formed from resin, and that can reduce the size and space of components formed from resin.

[0007] The present invention provides a stator assembly comprising a stator, a first through-portion that penetrates the stator in the axial direction, and a member formed of resin that covers the stator, wherein the member formed of resin has a second through-portion that penetrates the axial direction, the first through-portion and the second through-portion are arranged to be in communication with each other, and the dimensions of the first through-portion in a planar view are smaller than the dimensions of the second through-portion.

[0008] According to the present invention, two through-holes, each with its own function, are concentrated in one location, thereby simplifying the structure of the resin-made component and achieving miniaturization and space saving.

[0009] 11 is an exploded perspective view showing a resolver using a stator assembly according to a first embodiment of the present invention. (A) is a perspective view of the stator assembly according to the first embodiment, and (B) is an enlarged view of the portion indicated by arrow B in (A). (A) is a perspective view of the stator assembly according to the first embodiment as viewed from the rear side, and (B) is an enlarged view of the portion indicated by arrow B in (A). (B) is a cross-sectional view showing a terminal block. (C) is a cross-sectional view of the terminal block perpendicular to FIG. 4. (A) is a plan view of the terminal block, and (B) is an enlarged view of the portion indicated by arrow B in (A). (B) is a perspective view showing a resolver using a stator assembly according to a second embodiment of the present invention without a cover attached. (C) is a perspective view showing a resolver using a stator assembly according to a second embodiment. (A) is a plan view showing a stator stack in the stator assembly according to the second embodiment. (B) is a cross-sectional view taken along line B-B in (A). (B) is a cross-sectional view of the stator assembly according to the second embodiment. (C) is a cross-sectional view taken along line XII-XII in FIG. 11. 10A and 10B are rear views of a stator assembly according to a second embodiment. (A) is a plan view showing the periphery of a through hole in the stator assembly according to the second embodiment, (B) is a cross-sectional view taken along line B-B of (A), (C) is a cross-sectional view taken along line C-C of (A), and (D) is a cross-sectional view showing another cross section of (C). (A) is a plan view showing a flange in the stator assembly according to the second embodiment, and (B) is a cross-sectional view taken along line B-B of (A).

[0010] [1] First Embodiment 1. Overall Configuration of Resolver Fig. 1 shows a resolver 1 equipped with a stator assembly 100 according to a first embodiment of the present invention. The resolver 1 is a variable reluctance (VR) resolver. The resolver 1 has a rotor 10 and a stator assembly 100 having an annular structure. Covers 50 are attached to the stator assembly 100 from both the top and bottom in the axial direction.

[0011] The rotor 10 has a structure in which multiple thin-plate rotor cores are stacked in the axial direction and is fixed to the output shaft (not shown) of a rotating electrical machine such as a motor. The rotor 10 has a circular opening 10a, a non-circular outer periphery, and a key 11 that fits into a key groove formed on the outer periphery of the output shaft. In the following description, the direction of the output shaft is referred to as the "axial direction," a direction perpendicular to the axial direction is referred to as the "radial direction," and a direction of rotation around the output shaft is referred to as the "circumferential direction." The direction of the central axis of the annular stator assembly 100 coincides with the axial direction. The central axis of the annular stator assembly 100 coincides with the rotation axis of the rotor 10. The terms "up" and "down" refer to the up and down directions in FIG. 1 .

[0012] The thin rotor core that constitutes the rotor 10 is manufactured by pressing an electromagnetic steel plate into a non-circular shape. Multiple rotor cores are stacked in the axial direction and fixed by crimping at the portions indicated by reference numeral 12 in the figure to form the rotor 10.

[0013] The stator assembly 100 is disposed outside the rotor 10 and fixed to a housing (not shown) of the rotating electrical machine. A gap is provided between the rotor 10 and the stator assembly 100, allowing the rotor 10 to rotate inside the stator assembly 100. The housing is a component to which the stator assembly 100 of the resolver 1 is attached, and is provided with screw holes for fixing the stator assembly 100 of the resolver 1. The stator assembly 100 of the resolver 1 is attached to the housing by threading bolts into the screw holes.

[0014] The stator assembly 100 includes a stator stack 110. The stator stack 110 has a structure in which multiple thin plate-shaped stator cores are stacked in the axial direction. The stator stack 110 includes an annular core back 111, multiple teeth 112 protruding radially inward from the core back 111, and multiple flanges 114 protruding radially outward from the core back 111. The core back 111 has multiple first through holes (first through portions) 111a penetrating in the axial direction, formed at equal intervals and concentrically around the entire circumference of the core back 111. The flange 114 has arc-shaped stator holes 114a formed concentrically in the circumferential direction. Here, the first through portions include any of through holes, notches, holes, and apertures.

[0015] Between adjacent flanges 114, multiple (seven in this example) U-shaped notches 115 are formed, opening radially outward. The stator core is manufactured by pressing electromagnetic steel sheets. Multiple stator cores are stacked in the axial direction and secured by crimping at locations indicated by reference numeral 116 to form the stator stack 110. The notches 115 contact a positioning pin or the like (not shown) to position the stator stack 110 and the housing in the rotational direction. In addition to positioning, a bolt for securing the stator stack to the housing may be inserted through the notches 115. The diameter of the bolt is preferably such that the bolt does not come into contact with the stator stack 110 when inserted through the notches 115.

[0016] Insulators 150 are fixed to both axial sides of the stator stack 110. The insulators 150 are made of insulating resin and are injection-molded using the stator stack 110 as an insert material. The insulators 150 have windings 151. The windings 151 are formed to surround the entire circumference of the teeth 112 and include a tube 152 (see FIG. 4) in the radial center, a flange 153 that extends axially and circumferentially on the radially inner side of the tube 152, and protrusions 156, which will be described below. Note that the insulators 150 are not limited to those that are injection-molded; a separately formed insulator 150 can also be fixed to the stator stack 110. Alternatively, the insulator 150 can be structured such that the entire stator stack 110 is covered with resin by injection molding. In this case, during injection molding, a positioning pin for positioning the stator stack 110 and the housing in the rotational direction may be molded from resin, and a bolt insertion hole (a hole portion through which a bolt is inserted) for fixing to the housing may be integrally molded from resin using a metal collar.

[0017] The insulator 150 has an annular protrusion 154 that protrudes upward and downward in the axial direction. A wall 155 that protrudes upward in the axial direction and faces the flange 153 is formed on the inner periphery of the upper portion of the annular protrusion 154. Furthermore, as shown in FIG. 3B , a protrusion 156 that protrudes radially inward and faces the flange 153 is formed on the inner periphery of the lower portion of the annular protrusion 154. A conducting wire 157a (see FIG. 6A ) is wound around the tube 152 between the flange 153 and the wall 155 and protrusion 156 to form a coil 157.

[0018] A terminal block 200 having a rectangular shape in a plan view and protruding radially outward is integrally formed on the radially outer side of the annular protrusion 154. A plurality of terminals 210 (six in this example) are embedded in the terminal block 200 by insert molding, and are arranged with gaps between them in a horizontal direction (hereinafter referred to as the "horizontal direction") perpendicular to the radial direction. The terminals 210 are L-shaped in a side view and comprise a pin 211 protruding from the top surface of the terminal block 200 and a plate 212 extending radially outward from the lower end of the pin 211.

[0019] As shown in FIG. 4 , the terminal block 200 is formed with a groove 220 that extends radially and is open to the outside. The plate 212 is exposed in the groove 220. On the inner surface of the groove 220, multiple protrusions 221 that protrude circumferentially and extend axially are formed at positions radially spaced from the plate 212. The groove 220 also has multiple (six in this example) through-holes 222 that penetrate vertically. The rear surface of the terminal block 200 is formed with an arc-shaped recess 222a that encompasses all of the through-holes 222. The circumferential width of the terminal block 200 is greater than the circumferential width of the stator hole 114a of the stator stack 110 and covers the entire stator hole 114a. The recess 222a is formed in an arc shape to fit into the stator hole 114a, which reduces the amount of resin required by the recess.

[0020] The core wire of the lead wire is directly welded to the plate 212. A plurality of protrusions 221 protruding in the circumferential direction are formed on the inner surface of the groove 220, and the lead wire is fixed by being sandwiched between the protrusions 221 on one inner surface and the protrusions 221 on the other inner surface. The core wire and the plate 212 are sandwiched between electrodes of a resistance welding machine inserted into the groove 220 and the through hole 222, and are melted by passing a current through the electrodes.

[0021] As shown in FIG. 6A , a recess 230 is formed on the top surface of the terminal block 200. A protrusion 240 is formed radially inward of the terminal 210 in the recess 230, projecting upward from the bottom surface of the recess 230. As shown in FIG. 4 , the protrusion 240 has a surface that slopes upward in the axial direction as it approaches the pin 211 in the radial direction, a surface that slopes downward in the axial direction as it approaches the pin 211 in the radial direction, and a connection surface connecting these surfaces. The protrusion 240 is arranged so that the upwardly sloping surface, the connection surface, and the downwardly sloping surface approach the pin 211 in this order, and extends in a horizontal direction parallel to the arrangement of the terminals 210. As shown in FIG. 6B , upwardly rising walls 241 are formed on both lateral sides of the protrusion 240. A groove 242 is formed between the wall 241 and the wall 231 that forms the recess 230.

[0022] As shown in Fig. 6(A), the grooves 242 are formed at very close intervals. As a result, varnish (adhesive material) that accumulates in the recess 230 flows into the grooves 242 by capillary action and flows downward in Fig. 6(A) due to the difference in height. This structure makes it possible to prevent varnish from accumulating more than necessary in the recess 230. Furthermore, the grooves 242 may be formed so that their axial position decreases toward the bottom in Fig. 6(A), and in this case too, it is possible to prevent varnish from accumulating more than necessary in the recess 230.

[0023] The protrusion 240 has a second through hole (second through portion) 250 formed concentrically with the first through hole 111a of the core back 111. Therefore, the second through holes 250 are arranged in an arc shape. The circumferential positions of these first and second through holes 111a, 250 are approximately at the center of the gap between the terminals 210, and the first and second through holes 111a, 250 are radially opposed to the gap between the terminals 210. Furthermore, a second through hole 250 is also formed concentrically with the first through hole 111a on the rear surface side of the protrusion 240 (see FIG. 3B). The through hole 111a and the second through hole 250 do not have to be concentric. For example, the centers of the respective holes may be offset, as long as they are connected. Furthermore, the protrusion 240 is positioned radially between the first through hole 111a and the terminal 210. In other words, the protrusion 240 is located between the first through hole 111a and the recess 230. This structure can prevent an adhesive such as varnish applied to the recess 230 from leaking out of the through hole 111a. The second through portion includes any of a through hole, a notch, a hole, and a hole.

[0024] Bosses 260 that protrude upward are formed on both radially outer ends of the terminal block 200. The bosses 260 are positioned at positions shifted circumferentially outward from the terminals 210 on both ends. Similar bosses 260 are also formed on some of the walls 155 that support the coils 157. Also on the back side of the stator assembly 100, bosses 260 are formed on some of the protrusions 156 that support the coils 157.

[0025] Next, the cover 50 will be described with reference to FIG. 1 . The cover 50 is composed of an upper cover 51 and a lower cover 55. The upper cover 51 includes a flange 52 having a circular opening 52a in its center and a tube 53 extending axially from the peripheral edge of the flange 52. The inner periphery of the tube 53 contacts the outer periphery of the upper portion of the annular protrusion 154 of the stator assembly 100. A substantially rectangular terminal block cover 54 protruding radially outward is formed on one side of the tube 53. The inner periphery of the terminal block cover 54 contacts the outer periphery of the terminal block 200. A through-hole 54a is formed at both radially outer ends of the terminal block cover 54, penetrating in the axial direction. The flange 52 also has a plurality of (five in this example) through-holes 52b penetrating in the axial direction.

[0026] The lower cover 55 includes a flange 56 having a circular opening 56a in the center, and a cylinder 57 extending axially from the peripheral edge of the flange 56. The inner periphery of the cylinder 57 contacts the outer periphery of the lower portion of the annular protrusion 154 of the stator assembly 100. A substantially rectangular protrusion 58 that protrudes radially outward is formed on one side of the cylinder 57. The protrusion 58 covers the second through-hole 250 of the terminal block 200. The flange 56 is formed with a plurality of (five in this example) through-holes 56b that penetrate in the axial direction.

[0027] Bosses 260 are inserted into the through holes 52b, 56b, and the tips of the protruding bosses 260 are heat caulked to secure the upper and lower covers 51, 55 to the stator assembly 100. The flanges 52, 56 of the cover 50 cover the winding portion 151 and the coil 157 of the stator assembly 100 to protect the coil 157 from external forces. The terminal block cover 54 covers the terminal block 200 to prevent foreign matter from entering, and the protrusion 58 covers the second through hole 250 to prevent foreign matter from entering.

[0028] 2. Resolver Assembly Method i) Injection Molding The stator stack 110 and terminals 210 are set in a mold, and the mold is closed. At this time, the openings at both ends of the first through-hole 111a of the stator stack 110 located in the space where the terminal block 200 is molded are blocked with stack retainer pins of the mold, and the stator stack 110 is sandwiched between the stack retainer pins from above and below. When resin is injected into the mold in this state, the stator stack 110 is pressed from above and below by the stack retainer pins, preventing deformation of the stator core due to the molding pressure of the terminal block 200. Then, after the resin has hardened, the mold is opened, and the stack retainer pins are removed from the molded terminal block 200. This leaves behind second through-holes 250 where the stack retainer pins were removed.

[0029] ii) Wire Fixation Two loose pins are inserted from the lower sides of the first and second through-holes 111a and 250 and protrude from the second through-hole 250. Next, the wire 157a drawn from the coil 157 is hooked onto each of the two loose pins and wound around the pin 211 of the terminal 210. The wire 157a is wound around the pin 211 starting from a predetermined position slightly above the base of the pin 211 and ending at a predetermined distance below the top end of the pin 211. This operation is performed sequentially for each of the six pins 211. The end position of the wire tying is controlled using any device, such as a video device. In this case, the bosses 260 for securing the cover 50 are positioned circumferentially offset from the terminals 210 at both ends. Therefore, the bosses 260 do not obstruct the projection of the pins 211, and the end position of the wire tying can be controlled from the radial direction using any device, such as a video device.

[0030] Next, the slack pins are removed from the first and second through-holes 111a and 250. This creates slack in the conductor 157a, and the tensile stress that had been generated in the conductor 157a disappears. This slack rests on the top surface of the protrusion 240. This axial position is approximately the same as the axial position where the conductor 157a begins to be wound around the pin 211, so the conductor 157a is kept approximately horizontal. Note that the conductor 157a may be in a shape other than approximately horizontal, for example, a shape in which a portion of the conductor 157a protrudes in the axial direction.

[0031] Next, the portion of the pin 211 above the end of the binding is melted by welding means such as TIG welding. At this time, an inert gas such as argon and oxygen are sprayed onto the welding portion from above (in the radial direction) in Fig. 6(A) while adjusting the amount of melting of the pin 211 to adjust the height of the pin 211. In this case, since the boss 260 is positioned at a position offset in the circumferential direction from the terminals 210 at both ends, welding can be performed on the six pins 211 without the flow of the inert gas being obstructed by the boss 260.

[0032] iii) Application of Varnish Varnish is applied to the terminal block 200 and its surrounding area so as to cover the coil 157, the conductor 157a drawn from the coil 157, and the pin 211. Varnish that has flowed down into the recess 230 flows elsewhere through the groove 242, so that the necessary amount of varnish is accumulated rather than accumulating in the recess 230. This allows the top of the protrusion 240 and the conductor 157a to be fixed in place by the varnish. In addition, the coil 157 and the pin 211 to which the conductor 157a is fixed are covered with varnish.

[0033] iv) Attaching the Covers The upper cover 51 and the lower cover 55 are attached to the stator assembly 100. At this time, the bosses 260 of the stator assembly 100 are inserted into the through holes 52b of the upper cover 51 and the through holes 56b of the lower cover 55, and the bosses 260 of the terminal block 200 are inserted into the through holes 54a of the terminal block cover 54. Then, the tips of the bosses 260 protruding from the through holes 52b and 56b are thermally caulked. This fixes the cover 50 to the stator assembly 100.

[0034] In the stator assembly 100 configured as described above, the two through holes 111a, 250, each of which has a function, are concentrated in one location, so that the number of locations where the through holes 111a, 250 are provided can be reduced, and the configuration of the terminal block 200 can be simplified, thereby making the terminal block 200 smaller and more space-saving.

[0035] In particular, in the above embodiment, the first and second through holes 111a, 250 are radially opposed to the gaps between the multiple terminals 210, so that the loosening pin can be inserted at a position midway between the terminals 210 in the horizontal direction, thereby enabling the slack in the conductor 157a to be evenly provided.

[0036] In the above embodiment, the terminal block 200 is formed with the protrusion 240 that protrudes upward, so that the axial position of the conductor 157a placed on the top surface of the protrusion 240 can be made the same as the axial position at which the conductor 157a begins to be wound around the pin 211. This makes it easier to wind the conductor 157a and also makes it easier to fix the conductor 157a to the top surface of the protrusion 240 with varnish.

[0037] In the above embodiment, the conducting wire 157a can be brought into contact with the top surface of the protrusion 240, and the two can be reliably fixed with varnish. Furthermore, since the protrusion 240 overlaps with the first through-hole 111a in the axial direction, the loose portion of the conducting wire 157a can be fixed to the top surface of the protrusion 240. This prevents the loose portion from moving.

[0038] 3. Modifications The present invention is not limited to the above embodiment and various modifications are possible, as described below. i) In the above embodiment, the protrusion 240 and the conductor 157a are in contact with each other. However, this is not limiting. The protrusion 240 and the conductor 157a may face each other via an adhesive material such as varnish. ii) In the above embodiment, the terminal block 200 has one protrusion 240, but multiple protrusions 240 may be formed. Alternatively, multiple bosses may be formed facing the pin 211 instead of the protrusion 240. In this case, the circumferential or radial surfaces of the bosses and the conductor 157a can be fixed with varnish. iii) In the above embodiment, the terminal block 200 has one protrusion 240, but multiple bosses may be formed facing the pin 211 instead of the protrusion 240. In this case, the lateral surfaces of the bosses and the conductor 157a can be fixed with varnish.

[0039] iv) In the above embodiment, the protrusion 240 overlaps with the first through hole 111a in the axial direction, but the protrusion 240 can be disposed between the first through hole 111a and the terminal 210. v) In the above embodiment, the terminal connected to the lead wire is welded to the exposed plate 212 of the terminal 210, but it is also possible to form the terminal block 200 integrally with a connector housing, and to connect the connector to a terminal pin protruding into the connector housing.

[0040] vi) The cross-sectional shape of the second through holes 250 is not limited to a circle, and any shape may be used as long as it is larger than the diameter of the first through holes 111a. The key is to prevent resin from flowing into the first through holes 111a during injection molding. vii) The number of second through holes 250 is not limited to three, and any number is possible. For example, the number can be two, four, or six. viii) When forming the second through holes 250, if the stack holding pins are arranged in only one direction (only in the lower mold or only in the upper mold), the traces of the resin left by removing the stack holding pins can be formed as non-through holes with holes formed in only one direction.

[0041] [2] Second Embodiment A second embodiment of the present invention will be described with reference to Figures 7 to 15. 1. Overall Configuration of Resolver Figure 7 shows a resolver 2 equipped with a stator assembly 300 according to a second embodiment of the present invention. The resolver 2 is a VR-type resolver. The resolver 2 has a rotor 20 and a stator assembly 300. A cover 60 is attached to the stator assembly 300 from above in the axial direction.

[0042] The rotor 20 has a circular opening 20a and a non-circular outer periphery, and is fixed to an output shaft (not shown) of a rotating electrical machine such as a motor by an appropriate method such as adhesive or press-fitting. In the following description, the direction of the output shaft is referred to as the "axial direction," the direction perpendicular to the axial direction is referred to as the "radial direction," and the direction of rotation around the output shaft is referred to as the "circumferential direction." Furthermore, the terms "up" and "down" refer to the up and down directions in FIG. 12 .

[0043] The stator assembly 300 is disposed outside the rotor 20 and fixed to a housing (not shown) of the rotating electrical machine. A gap is provided between the rotor 20 and the stator assembly 300, allowing the rotor 20 to rotate inside the stator assembly 300. The housing is a component to which the stator assembly 300 of the resolver 1 is attached, and is provided with screw holes for fixing the stator assembly 300 of the resolver 2.

[0044] The stator assembly 300 includes a stator stack 310 (see FIG. 9 ). The stator stack 310 has a structure in which multiple thin-plate stator cores are stacked in the axial direction. The stator stack 310 includes an annular core back 311, multiple teeth 312 protruding radially inward from the core back 311, and multiple notches (first through-holes) 314 recessed radially inward from the core back 311. The notches 314 extend circumferentially and are formed at equal intervals around the entire circumference of the core back 311.

[0045] Insulators 350 are fixed to both axial sides of stator stack 310. Insulator 350 is made of insulating resin and is injection molded using stator stack 310 as an insert material. Insulator 350 covers the entire stator stack 310 except for specified areas. The specified areas not covered by insulator 350 are the surfaces of teeth 312 facing the inner periphery and the portions exposed by through-holes (second through-hole portions) 360 and holes 370, which will be described later.

[0046] 12, the insulator 350 includes a tube 352 in the radial center, a flange 353 that extends in the axial and circumferential directions on the radially inner side of the tube 352, and a protrusion 356 that extends in the axial direction. Note that the insulator 350 is not limited to being injection molded, and a separately formed insulator 350 can also be fixed to the stator stack 310. A conducting wire is wound around the tube 352 to form a coil 357.

[0047] The insulator 350 has an annular protrusion 354 that protrudes upward and downward in the axial direction. A terminal block 400 that has a rectangular shape in a plan view and protrudes radially outward is integrally formed on the radially outer side of the annular protrusion 354.

[0048] 10 , a plurality of terminals 410 (six in this example) are embedded by insert molding in the terminal block 400. The terminals 410 are arranged at intervals in a horizontal direction (hereinafter simply referred to as the “horizontal direction”) perpendicular to the radial direction. Each terminal 410 is bent at three points to form a generally L-shape in side view, and is made up of a pin 411 protruding from the top surface of the terminal block 400 and a plate 412 extending radially outward from the lower end of the pin 411.

[0049] Grooves 420 that extend radially and are open to the outside are formed in the terminal block 400. The grooves 420 are formed corresponding to the respective terminals 410, and plates 412 are exposed at the bottom surfaces of the grooves 420. The lateral spacing between the grooves 420 is set wider than the spacing between the terminals 410. Therefore, the plates 412 are arranged offset from the pins 411 in the lateral direction.

[0050] The core wire of the lead wire is directly welded to the plate 412. A through hole 422 that communicates with the groove 420 is formed below the groove 420, and the core wire and the plate 412 are sandwiched between electrodes (not shown) of a resistance welding machine inserted into the groove 420 and the through hole 422, and are melted by passing a current through the electrodes.

[0051] A protrusion 440 is formed on the upper surface of the terminal block 400, and a pin 411 protrudes from the upper surface of the protrusion 440. This brings the position of the conductor wire drawn from the coil 357 close to the base of the pin 411, and the entanglement work of the conductor wire can be started from the base of the pin 411. This suppresses shaking of the pin 411 during the entanglement work, and allows the entanglement work to be carried out smoothly.

[0052] The insulator 350 has multiple (seven in this example) through holes 360 formed at equal intervals in the circumferential direction. The through holes 360 are oval and are formed at the positions of the notches 314 in the stator stack 310. A first pin (described later) that forms the through holes 360 allows the stator stack 310 to be stably held within the mold during injection molding. Furthermore, in a plan view, a portion of the notches 314 is contained within the through holes 360. In other words, the circumferential dimension of the notches 314 is smaller than the dimension of the through holes 360. The notches 314 in the stator stack 310 are open in both the axial and radial directions, and the insulator 350 covers the openings facing the radial direction, thereby forming the through holes 360 that are open in the axial direction. In other words, the notches 314 face the insulator 350 in the radial direction. 14B, the insulator 350 is configured to cover a portion of the notch 314 in the axial direction, thereby improving the heat resistance and vibration resistance of the resolver 2 and providing protection and rust prevention for the stator stack 310.

[0053] 13, holes 370 are formed on the back surface of the insulator 350, reaching the stator stack 310. The holes 370 are pin marks used to position the stator stack 310 in a floating position in the mold when the insulator 350 is injection molded using the stator stack 310 as an insert material. As shown in FIGS. 13 and 14(D), a through-hole 320 is formed in the stator stack 310 facing one of the holes 370.

[0054] A plurality of flanges 380 (three in this example) protruding radially outward are formed at equal intervals in the circumferential direction on the outer periphery of the insulator 350. As shown in Fig. 15, a through hole 381 is formed in the flange 380, and a metal collar 382 is integrally formed in the through hole 381 by insert molding. A bolt is inserted into the collar 382, ​​and the resolver 2 can be attached to the rotating electric machine by threading the bolt into a threaded hole formed in the housing of the rotating electric machine.

[0055] Next, the cover 60 will be described with reference to Figure 8. The cover 60 includes a flange 62 having a circular opening 62a in the center, and a tube 63 extending axially from the peripheral edge of the flange 62. The inner periphery of the tube 63 contacts the outer periphery of the upper portion of the annular protrusion 354 of the stator assembly 300. A substantially rectangular terminal block cover 64 that protrudes radially outward is formed on one side of the tube 63. The inner periphery of the terminal block cover 64 contacts the outer periphery of the protrusion 440.

[0056] 2. Resolver Assembly Method The procedure for injection molding the insulator 350 using the stator stack 310 as an insert material will be described. Pins are provided in the lower part of the injection mold to support the stator stack 310 in a floating state within the mold. The pins are positioned corresponding to the holes 370 in the insulator 350. One of the pins has a small diameter portion that is inserted into a through hole 320 formed in the stator stack 310. The small diameter portion extends over the entire length of the through hole 320 and prevents resin from entering the through hole 320.

[0057] The upper and lower mold halves are provided with a first pin for forming the through-hole 360 ​​in the insulator 350 and a second pin for preventing resin from entering the notch 314 in the stator stack 310. When the stator stack 310 is placed in the mold, the notch 314 is aligned with the second pin. The small-diameter portion of the pin is inserted into the through-hole 320 formed in the stator stack 310 to position the stator stack 310 circumferentially. When the stator stack 310 is placed on the pins of the lower mold and the first pin and the upper and lower molds are closed, the stator stack 310 is sandwiched between the first pin, preventing deformation of the stator stack 310 due to molding pressure. The second pin limits the circumferential and radial movement of the stator stack 310, preventing misalignment of the stator stack 310 within the mold.

[0058] After the injection molding is completed, the upper and lower molds are opened, and the substantially completed stator assembly 300 is removed from the mold. In the substantially completed insulator 350 of the stator assembly 300, the pin and the first pin form the hole 370 (only on the back surface) and the through-hole 360, and the second pin forms the notch 314 as a cavity. Then, the cover 60 is placed over the outer periphery of the annular projection 354 and the protrusion 440 of the insulator 350 and fixed by an appropriate means such as adhesive, thereby completing the stator assembly 300.

[0059] In the resolver 2 according to the second embodiment, the notches 314 and the through holes 360 are arranged to communicate with each other, and the dimensions of the notches 314 are smaller than the dimensions of the through holes 360. Therefore, the stator stack 310 can be positioned within the mold simply by placing the stator stack 310 on the first pin. Furthermore, the cavity formed in the notch (recess recessed in the radial direction) 314 and the through holes 360 are concentrated in one location, which reduces the number of locations where the cavity in the notch 314 and the through holes 360 are provided, thereby simplifying the configuration of the stator assembly 300.

[0060] In the resolver 2 of the second embodiment described above, when mounting holes (mounting portions) for the housing of the rotating electrical machine, such as the through-hole 381, and positioning pin holes are integrated with the insulator 350 by injection molding, molding precision of the insulator 350 is required. However, by fixing the notch 314 of the stator stack 310 with the first pin and the second pin, it is possible to position and hold the stator stack 310 within the mold.

[0061] In particular, in the second embodiment described above, the notch 314 is used as the first penetration portion, so the positional relationship between the notch 314 and the second pin can be visually confirmed, and further, since the outer periphery of the stator stack 310 is aligned with the second pin, the alignment work is simple and accurate.

[0062] Furthermore, since the notch 314 extends in the circumferential direction, the second pin inserted into the notch 314 is large and flat, making it easy to see, and the contact area with the second pin is large, thereby improving positioning accuracy.

[0063] In the second embodiment described above, one through hole 320 is formed in the stator stack 310, and the circumferential positioning of the stator stack 310 can be performed by inserting the small diameter portion of the mold pin into the through hole 320.

[0064] Furthermore, in the second embodiment, holes 370 are formed in the insulator 350 that reach the stator stack 310. This allows the stator stack 310 to be placed on the pins of the mold used to form the holes 370, in addition to the first pins, and the stator stack 310 can be stably supported within the mold.

[0065] 3. Modifications The present invention is not limited to the second embodiment, and various modifications are possible as follows: i) The notch 314 may be replaced with a through hole.

[0066] ii) The holes 370 and through-holes 320 can be omitted. iii) The through-holes 360 are not limited to an oval shape, and can be any shape, such as a circle. In other words, any shape is acceptable as long as it can secure the stator stack 310 during injection molding. iv) The number of through-holes 360 formed at the position of the stator stack 310 can be set as desired depending on the size of the stator stack 310, the mold, the resin molding conditions, etc.

[0067] v) The notches 314 of the stator stack 310 correspond to the positions of the teeth 312 and can direct the magnetic flux flowing through the core back 311 toward the teeth 312. When the magnetic flux changes direction toward the teeth 312 just before reaching the notches 314, leakage of the magnetic flux into the notches 314 can be suppressed.

[0068] The present invention can be used in a stator assembly of an angle sensor that detects the rotation angle of a rotating electrical machine such as a motor or a generator.

[0069] DESCRIPTION OF SYMBOLS 1, 2... resolver, 10, 20... rotor, 10a, 20a... opening, 11... key, 50, 60... cover, 51... upper cover, 52a, 62a... opening, 52b... through hole, 52, 62... flange, 53, 63... cylinder, 54, 64... terminal block cover, 54a... through hole, 55... lower cover, 56... flange, 56a... opening, 56b... through hole, 57... cylinder, 58... protrusion, 100, 300... stator assembly, 110, 310... stator stack, 111, 311... core back, 111a... first through hole (first through portion), 112, 312... teeth, 114... flange, 114a... stator hole, 115... notch, 150, 350... insulator, 151... winding portion , 152, 352... cylinder, 153, 353... flange, 154, 354... annular protrusion, 155... wall, 156, 356... protrusion, 157, 357... coil, 157a... conducting wire, 200, 400... terminal block, 210, 410... terminal, 211, 411... pin, 212, 412... plate, 220, 420... groove, 221... protrusion, 222, 422 ...through hole, 222a...recess, 230...recess, 231...wall, 240, 440...protrusion, 241...wall, 242...groove, 250...second through hole (second through portion), 260...boss, 314...notch (first through portion), 320...through hole, 360...through hole (second through portion), 370...hole, 380...flange, 381...through hole, 382...collar.

Claims

1. A stator assembly comprising: a stator; a first through-portion that penetrates the stator in the axial direction; and a member formed of resin that covers the stator, wherein the member formed of resin has a second through-portion that penetrates the axial direction, the first through-portion and the second through-portion are arranged to communicate with each other, and the dimensions of the first through-portion in a plan view are smaller than the dimensions of the second through-portion.

2. The stator assembly according to claim 1, wherein the member made of resin forms a terminal block.

3. A stator assembly as set forth in claim 2, wherein the stator has an annular structure, the terminal block includes a plurality of terminals to which conductor wires are connected, the plurality of terminals are arranged with gaps between them in the circumferential direction around the central axis of the annular structure, and the first through-portion faces the gap in the radial direction.

4. A stator assembly according to claim 3, wherein the terminal block has a protrusion that protrudes in the axial direction, and the protrusion fixes the conductor wire via an adhesive member.

5. A stator assembly according to claim 4, wherein the protrusion overlaps with the first through-portion in the axial direction.

6. A stator assembly according to claim 4, wherein the protrusion is located between the first through-portion and the terminal in the radial direction.

7. A stator assembly according to any one of claims 4 to 6, wherein the protrusions are made up of a plurality of bosses, each of which has a wall facing in a circumferential direction around the central axis, and the wall fixes the conductor wire via the adhesive member.

8. A stator assembly according to claim 1, wherein the member made of resin forms an insulating member that covers the stator.

9. A stator assembly according to claim 8, wherein the insulating member has a hole extending to the stator.

10. A stator assembly according to claim 1 or 2, wherein the stator has an annular structure, and the first through-portion is a notch extending in the circumferential direction around the central axis of the annular structure on the outer periphery of the stator.

11. A stator assembly according to claim 10, wherein the second through-portion is an oval through-hole extending along the notch.

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