JP5368825B2 - Manufacturing method of motor stator - Google Patents

Abstract

The invention discloses a manufacturing method for motor stator, motor stator and compressor. The technical matters that will be solved in this invention is to obtain a method for manufacturing coils with high insulating reliability and motor stator with high performance. In this invention, a face is protruded from the back yoke (21) and is assembled with multiple tensed tooth pairs (24a)-(24c) of a insulator(23), when a face is winded with multiple layers of windings, the tention applied to the next layer(12) of the winds reduces the tention of the first layer(11) of the windings contacting directly with the insulator(23).

Description

The present invention, coil the teeth of the stator core of the motor is relates to the production how the motor stator to be wound directly wound.

  In recent years, a rotary motor such as an induction motor is often used as a direct-winding motor of a brushless DC motor in order to reduce the size and increase the performance. In this motor stator, a plurality of teeth are provided at equal intervals around the inner surface or the outer surface, and the entire circumference, or the upper surface portion and / or the lower surface portion thereof is covered with an insulator of a resin-molded insulating member. It is configured by winding a coil directly around the broken teeth.

  On the other hand, in view of the need for higher density of coils wound around the stator for higher performance, the amount of coil winding may be increased. In order to increase the amount of winding, it is important to arrange the coils wound around the teeth in an orderly manner. A tension control device is always installed between the supply wire and the nozzle of the winding machine. A constant tension is applied to the wire.

  An arrangement of coils wound around a general electric motor stator will be described with reference to FIGS. 3 and 4. 3 and 4 are sectional views showing a series-winding motor stator. The stator core 10 has a plurality of teeth 24a, 24b, 24c and the like protruding from the back yoke 21, and is covered with an insulator 23 which is an insulating member. In the case of the teeth 24a, the wire passes through the insulator 23 to the teeth 24a in a plurality of layers in order of the first winding layer 11, the second winding layer 12, the third winding layer 13, and the fourth winding layer 14. It is wound directly.

  The winding first layer 11 is wound in the direction b from the back yoke 21 side of the stator core 10. Thereafter, the winding second layer 12 is in the a direction on the back yoke 21 side and the winding third layer 13. Is wound in the b direction from the back yoke 21 side, and the winding fourth layer 14 is wound with the a direction on the back yoke 21 side and the traveling direction alternately changed. At this time, a gap 22a is generated at the outer periphery of the fourth layer of the winding.

  On the other hand, for higher performance, there is a need to increase the density of the coils wound around the stator. The teeth 24b and 24c represent a state in which the winding 5th layer 15 and the winding 6th layer 16 are further wound around the outer periphery of the winding 4th layer 14. In this state, the gap 22b between the teeth 24b and 24c is reduced as compared with the tooth 22a, and the amount of the wound coil is increased. The teeth 24a and all the other teeth can achieve higher performance of the stator by winding a coil in the same manner as the teeth 24b and 24c.

  In order to achieve high performance as described above, it is necessary to wind the coil at a high density. For that purpose, it is important to arrange the wound coils in an orderly manner.

  The arrangement of the coils of the second winding layer 12 wound around the teeth 24a of FIG. 4 needs to be regularly arranged in the center position between the coils of the first winding layer 11 wound previously. is there. For example, if the aim of the coil to be arranged in the normal coil arrangement 17a is shifted to the arrow b side, the coil 2 is arranged at the position of the coil arrangement deviation 17b, which is the outer peripheral portion of the second winding layer 12, and if it is shifted to the arrow a side, the winding 2 It will be arranged at the position of the coil arrangement deviation 17c on the core back 21 side of the layer 12.

  For this reason, no coil is arranged in the portion of the normal coil arrangement 17a which is the original arrangement destination, and the coil arrangement deviation 17c or the coil arrangement adjacent to the coil arrangement deviation 17b is sequentially performed at the time of subsequent coil winding. The alignment is broken and the coil cannot be wound with high density.

  As a countermeasure against the disturbance in the arrangement of the coils as described above, a tension device that applies a tension to the wire to be wound to improve the arrangement accuracy of the coil is used. In a tension device of a general winding machine for a direct-winding motor stator, tension is applied by relaying a wire to a commercially available drum brake, a movable pulley using a compression force of a spring, or a thrust of an air cylinder.

  The operation of the tension device having the above configuration will be described. When a strong braking force is applied to the drum brake while the coil is wound, the tension applied to the wire increases, and the movable pulley to which the wire is relayed is a spring or an air cylinder. The position is moved by the compression action, and a command to loosen the braking force is issued to the drum brake by a signal from a position detection sensor or the like. When the braking force of the drum brake is loosened, the tension applied to the wire decreases, so the movable pulley moves to the original position by the extension action of the spring or air cylinder, and the braking force of the drum brake is detected by a signal from the position detection sensor etc. Strengthen again.

As described above, the tension applied to the wire by changing the braking force of the drum brake causes the movable pulley position to move in a timely manner by the compression or extension of the spring or the air cylinder, so that a constant tension is applied to the wire. . In some cases, tension is applied by holding the wire with a pressing plate instead of the movable pulley.
In either case, the purpose is to always apply a constant tension to the wire being wound, thereby improving the coil placement accuracy.

  Further, as a coil winding method for always applying a constant tension to the wire, for example, “... the control means detects the load acting on the central tension roller 12b by the load converter 12d, thereby The wire drum 9 is provided with a drum brake 9b, and the control means controls the wire drum 9 by the drum brake 9b so that the detected value of the load converter 12d becomes equal to the set tension. Has been proposed (for example, see Patent Document 1).

Japanese Patent Laid-Open No. 7-201601 ([0011], FIG. 1)

  Using the tension device of the winding machine for a series-winding motor stator of the conventional example (including Patent Document 1) as described above, the entire circumference of the teeth around the inner surface or the outer surface of the stator core, or the upper surface portion and In the case where a wire is wound around an electric motor stator covered with a resin-molded insulator, either the lower surface portion or any one of them, there are the following problems, which will be described with reference to FIG.

FIG. 5 is a perspective view of one tooth of the series-winding motor stator.
On the surface of the insulator 23 attached to the stator core 10, due to the influence of wear of a mold for manufacturing the insulator 23, a step 30 due to a parting line that is a joint of the mold at the time of resin molding, There may be a sharp burr 31.

  In addition, motor stators used in compressors that compress refrigerants are required to have heat resistance and extraction resistance against refrigerants. For this reason, since durability and intensity | strength are required for the insulator 23, glass fiber may be added to resin which is the material of the insulator 23. FIG. As described above, the surface roughness of the insulator 23 to which the glass fiber is added becomes rougher than that of the non-added product, and the partially exposed glass fiber 32 may exist on the surface of the insulator 23.

  When such a insulator is used and a coil is wound over multiple layers using a tension device for a winding machine for a series-winding motor stator of a conventional example, a constant tension is always applied to the wire 1. Therefore, a stress is generated on the inside of the coil, that is, on the insulator 23 side. At this time, the coil of the first layer 11 of the winding may be strongly pressed against the step 30 due to the parting line existing on the surface of the insulator 23, the sharp burr 31 or the exposed glass fiber 32. May deteriorate and insulation reliability may deteriorate.

  The present invention has been made in order to solve the above-described problems, and a first object is to manufacture a motor stator capable of manufacturing a high-performance motor stator having high insulation reliability of coils. There is to get a way.

The method for manufacturing an electric motor stator according to the present invention is an electric motor stator manufacturing method in which a plurality of layers of a coil are wound while applying tension to a plurality of teeth portions each protruding from a back yoke portion and incorporating an insulator. When winding the coil of the first layer of the winding that is in direct contact with the insulator, a constant first tension is applied to the coil, and when winding the coils of all the layers after the second layer of winding, the coil When a constant second tension is applied to the first tension x and the second tension is f, the first tension x is in the range of 2 / 5f ≦ x ≦ 3 / 5f and constant tension. .

According to the method of manufacturing the motor stator of the present invention, the tension applied to the coil wound around the first layer (lowermost layer) of the winding that is in direct contact with the insulator (first tension) is applied to the second and subsequent layers of the winding. The tension is less than the tension (second tension) applied to the coils of all the layers, and when the second tension is f, the first tension x is in the range of 2 / 5f ≦ x ≦ 3 / 5f. Since the coil is configured to have a constant tension, the insulation film of the coil in the first winding layer (the bottom layer) is prevented from being deteriorated while winding the coil at a high density, and a high-performance motor stator is manufactured. be able to.

It is a front view which shows the tension apparatus of the winding machine in Embodiment 1 of this invention. It is a front view which shows the tension apparatus of the winding machine in Embodiment 1 of this invention. It is sectional drawing which shows a direct winding type motor stator. It is sectional drawing which shows a direct winding type motor stator. It is a perspective view which shows the part for 1 teeth of a direct winding type motor stator. It is sectional drawing which shows the electric motor stator in Embodiment 1 of this invention. It is sectional drawing which shows the electric motor stator in Embodiment 1 of this invention.

Embodiment 1 FIG.
The first embodiment will be described with reference to FIGS. 1 to 3 and FIGS. The description of the same reference numerals as those in FIGS. 3 to 5 is omitted. 1 and 2 are front views showing a tension device for a winding machine according to Embodiment 1 of the present invention, and FIGS. 6 and 7 are sectional views of an electric motor stator according to Embodiment 1 of the present invention.

  The tension device of the winding machine shown in FIGS. 1 and 2 is freely movable by the pressure of the air cylinders 7a and 7b, and the first and second fixed pressing plates 8a and 8b made of ceramic, super steel or sapphire. And a first movable pressing plate 9a and a second movable pressing plate 9b made of a material such as ceramic, super steel or sapphire. As shown in the figure, two or more sets of the pressing plates (8a, 9a, 8b, 9b) are mounted.

Next, the operation will be described.
In the tension device for a winding machine configured as described above, the state shown in FIG. 1 is that the first movable holding plate 9a is moved to the first fixed holding plate 8a side by the forward thrust of the air cylinder 7a. The wire 1 is sandwiched between the plate 9a and the first fixed pressing plate 8a. On the other hand, since the air cylinder 7b is retracted, a gap is generated between the second movable pressing plate 9b and the second fixed pressing plate 8b, and the wire 1 is not clamped.

  In the state shown in FIG. 2, the air cylinders 7a and 7b are both moved forward, and by the thrust, between the first movable pressing plate 9a and the first fixed pressing plate 8a and between the second movable pressing plate 9b and the second fixed pressing plate. The wires 1 are sandwiched between the plates 8b.

  Furthermore, when the thrusts of the air cylinders 7a and 7b are made equal, in FIG. 2, the tension applied to the wire 1 by the thrusts of both the air cylinders 7a and 7b is defined as f. On the other hand, in FIG. 1, the tension applied to the wire 1 by the thrust of only the air cylinder 7a is f / 2.

  Thus, using the tension variable mechanism, the first winding layer 11 shown in FIG. 3 is wound with the tension f / 2 applied to the wire 1 by the thrust of only the air cylinder 7a of FIG. From the layer 12 onward, the wire 1 is wound with a tension f applied by the thrust of the air cylinders 7a and 7b in FIG.

Here, the operation of varying the tension will be described with reference to FIG.
7 is wound from the back yoke 21 side toward the tip of the tooth 24a. The winding first layer final coil 20 is a coil wound at the end of the winding first layer 11. The tension is varied by the air cylinder 7b that operates the second movable pressing plate 9b. The air cylinder 7b is operated by issuing a command by a winding quantity counter signal or the like.

  The operation timing of the air cylinder 7b for increasing the tension applied to the wire 1 is the number of windings of a winding flyer and a nozzle (not shown) as loads, that is, when the winding first layer final coil 20 finishes winding. It is. The adjustment of the operation timing is performed in consideration of the calculation delay of the control device and the delay until the operation of the air cylinder 7b is completed, so that a command is issued in advance several turns before the winding amount of the first coil of the first layer of the winding. This is a simple method that only requires a numerical value change setting such as a counter.

  Further, the setting of the operation command for the air cylinder 7b is governed by the winding quantity, and no complicated command setting adjustment is required unless the winding speed is changed extremely. Further, control by time from the start of winding is not necessary.

  As described above, the winding first layer 11 is wound with f / 2, that is, a weaker tension applied to the wire. If the tension applied to the coil wound as described above is less than the appropriate tension, the winding is wound. The arrangement accuracy of the coil is reduced. In this case, a gap d is generated between the coils of the first winding layer 11 as shown in FIG.

  However, since the tension applied to the coil of the first winding layer 11 is less than the appropriate tension applied for the original alignment as described above, the stress on the inside of the coil, that is, the insulator 23 side is It is weaker than the second winding layer 12 to which the appropriate tension is applied, and the arrangement of the coil can be moved when a force is applied from the outside.

  On the other hand, when the winding first layer final coil 20 is wound, stress is generated in the direction of arrow c in the winding first layer final coil 20. For this reason, the coil of the first winding layer 11 shown in FIG. 7 is pushed out in the direction of arrow a by the final coil 20 of the first winding layer, and the gap d generated between the coils of the first winding layer 11 is reduced. To do. That is, the coil is arranged at a target arrangement destination. After the second winding layer 12 in which the lower layer exists, the arrangement of the coil once wound by being constrained by the lower coil is difficult to correct to the normal position, but the winding of the first winding layer 11 which is the lowermost layer is difficult. Placement correction is possible.

  As described above, for the high-density winding of the coil, it is important to arrange the wound coils in an orderly manner, and the arrangement of each coil is each coil arranged in the lower layer previously wound. It is necessary to arrange them regularly in a central position between them. However, since the lower layer is not present in the first winding layer 11 which is the lowermost layer and the tension applied to the wire 1 is reduced, the coil arrangement can be corrected as described above.

  After completing the winding of the first coil 11 of the winding, when the second winding layer 12 is wound, the air cylinder 7b is advanced as shown in FIG. 2, and the second movable holding plate 9b and the second fixed are fixed by the thrust. The wire 1 is also sandwiched between the holding plate 8b and the wire 1 is given a tension f, that is, an original higher tension.

By the way, if the range of tension applied to the coil 1 when winding the first winding layer 11 is x, if 2 / 5f > x, the tension applied to the wire 1 is too low, and the first winding layer The stress on the inner side of the coil 11, that is, the insulator 23 side is weakened. For this reason, the coil of the first layer 11 of the winding may move too much in the direction of the arrow a by the final coil 20 of the first layer of winding, and it is difficult to correct the coil arrangement to the normal position.

In addition, in the case of 3 / 5f < x, the tension applied to the wire 1 is too high, the stress on the inner side of the coil of the first winding layer 11, that is, the stress on the insulator 23 side is also increased, and the amount of movement of the coil is restricted. For this reason, it is difficult to correct the normal position. Furthermore, there is a possibility that the insulating film will be strongly pressed against the step 30, the sharp burr 31 or the exposed glass fiber 32 due to the parting line existing on the surface of the insulator 23, and this influence may deteriorate the insulation film and lower the insulation reliability. There is.

The tension range x to be applied to the coil 1 when winding the first winding layer 11 is as follows.
2 / 5f ≦ x ≦ 3 / 5f
Is desirable.

  1 and 2 show an example in which two sets of tension devices are used, the number of tension devices can be further increased. Even if the number of tension devices is increased, if the tension f applied to the wire 1 is set to be the same, the clamping force to the wire 1 per set of tension devices is reduced, and the frictional force between each pressing plate and the wire 1 is reduced. Can be reduced.

  As described above, the first layer 11 of the winding 11 is wound by applying the necessary minimum tension capable of correcting the alignment and arrangement to the wire 1, so that the step 30 by the parting line and the sharp burrs are formed on the surface of the insulator 23 as shown in FIG. 5. Even if it exists in 31 or exposed glass fiber 32, it can prevent that wire 1 is pressed against these with strong force, and can prevent deterioration of the insulating film of wire 1 by contact with these. Therefore, an electric motor stator using a resin in which glass fiber is added to the insulator material can be manufactured.

  Further, since the proper proper tension f is applied to the wire 1 in the second and subsequent layers of the winding, it is possible to manufacture an electric motor stator in which the coil placement accuracy is improved and the coil is wound at high density.

  Furthermore, by manufacturing the motor stator using the above-described apparatus, it is possible to provide a high-performance motor stator with high insulation reliability that prevents deterioration of the insulating film of the wire 1.

  Furthermore, a high-performance compressor with high insulation reliability can be provided by incorporating an electric motor having the above-described electric motor stator into the compressor.

Embodiment 2. FIG.
In the first embodiment described above, the tension applied to the wire is varied by increasing / decreasing the number of use of the holding plate for pinching the wire. A second embodiment for changing the tension to be applied will be described with reference to FIGS. The description of the same reference numerals as those in the background art and the first embodiment is omitted.

  In FIG. 1 and FIG. 2, the tension is varied by operating one air cylinder 7b of the two sets of tension devices, but both air cylinders 7a and 7b are operated in advance as shown in FIG. By controlling the air valve (not shown) for supplying air pressure to the cylinders 7a and 7b to low pressure and high pressure, the thrust of the air cylinders 7a and 7b can be changed to low pressure, that is, weak tension, and high pressure, that is, strong tension. And may be applied to the wire 1.

  When the tension applied to the wire 1 when the pressure supplied to the air cylinders 7a and 7b is set to high is f, the tension range x applied to the coil 1 at low pressure is 2 / 5f ≦ x ≦ as described above. A setting of 3 / 5f is desirable. 3 is supplied with a low pressure to the air cylinders 7a and 7b, is wound with a weak tension applied to the wire 1, and is wound when the winding second layer 12 is wound after completion. A high pressure is supplied to 7a and 7b, and the tension is applied to the wire 1 by the thrust force, that is, the original higher tension.

  Further, since the switching timing of the pressure supplied to the air cylinders 7a and 7b is operated by issuing a command by a winding quantity counter signal or the like as in the first embodiment, the setting of the operation command is governed by the winding quantity. As long as there is no extreme change in the winding speed, complicated command setting adjustment is not necessary. Moreover, control by the time from the start of winding is also unnecessary.

  In addition, when the air pressure supplied to the air cylinders 7a and 7b is switched from low pressure to high pressure, only the thrust of the air cylinders 7a and 7b changes. Therefore, the operation of the first movable pressure plate 9a and the second movable pressure plate 9b is actually performed. No, the response from the operation command is high.

  Further, FIGS. 1 and 2 show an example in which two sets of tension devices are used, but a plurality of tension devices can be further increased. Even if the number of tension devices is increased, if the tension f at the time of strengthening applied to the wire 1 is set to be the same, the clamping force to the wire 1 per set of tension devices is reduced, and the holding plate and the wire 1 Frictional force can be reduced.

  As described above, the first layer 11 of the winding 11 is wound by applying the necessary minimum tension capable of correcting the alignment and arrangement to the wire 1, so that the step 30 by the parting line and the sharp burrs are formed on the surface of the insulator 23 as shown in FIG. 5. Even if it exists in 31 or exposed glass fiber 32, it can prevent that wire 1 is pressed against these with strong force, and can prevent deterioration of the insulating film of wire 1 by contact with these. Therefore, an electric motor stator using a resin in which glass fiber is added to the insulator material can be manufactured.

  In addition, since the proper proper tension f is applied to the wire 1 in the second and subsequent layers of the winding, it is possible to manufacture an electric motor stator in which the coil placement accuracy is improved and the coil is wound at a high density.

  Furthermore, by manufacturing the motor stator using the above-described apparatus, it is possible to provide a high-performance motor stator with high insulation reliability that prevents deterioration of the insulating film of the wire 1.

  Furthermore, a high-performance compressor with high insulation reliability can be provided by incorporating an electric motor having the above-described electric motor stator into the compressor.

Embodiment 3 FIG.
In the first and second embodiments described above, the tension applied to the wire is varied by pinching the wire with the pressing plate. However, the tension applied to the wire is varied when the conventional tension device is used next. A third embodiment will be described with reference to FIGS. The description of the same reference numerals as those in the background art and the first and second embodiments is omitted.

  A first movable holding plate 9a, a first fixed holding plate 8a and an air cylinder 7a as shown in FIGS. 1 and 2 are additionally installed in a conventional tension device.

  When the coil of the first layer 11 is wound, the brake of a drum brake (not shown) that applies tension to the wire 1 is released, and air pressure is supplied to the forward movement side to the additionally installed air cylinder 7a. The first movable holding plate 9a is moved forward to the first fixed holding plate 8a side, and the wire 1 between the first movable holding plate 9a and the first fixed holding plate 8a is clamped to give tension to the wire 1. .

  Further, when winding the coil of the second layer 12 of winding, a drum brake (not shown) that applies tension to the wire 1 is braked, and air pressure is supplied to the backward side of the additionally installed air cylinder 7a. The first fixed pressing plate 8a and the first movable pressing plate 9a are opened, and tension is applied to the wire 1 by a conventional tension device.

  Further, when the tension applied to the wire 1 at this time is f, when the winding first layer 11 is wound, the additional gap between the first movable pressing plate 9a and the first fixed pressing plate 8a is provided. The tension range x applied to the wire 1 when the wire 1 is sandwiched and wound is desirably set to 2 / 5f ≦ x ≦ 3 / 5f as described above.

  Furthermore, since the switching timing of the pressure supplied to the air cylinder 7a is operated by issuing a command by a winding quantity counter signal or the like as in the first and second embodiments, the setting of the operation command is set to the winding quantity. As long as there is no extreme change in the winding speed, complicated command setting adjustment is unnecessary. Moreover, control by the time from the start of winding is also unnecessary.

  In addition, the tension device has been described above with an example in which one set of the first movable pressing plate 9a, the first fixed pressing plate 8a, and the air cylinder 7a has been installed, but the second movable pressing plate 9b, The second fixed pressing plate 8b and the air cylinder 7b may be added to form two sets of tension devices to be added, or a plurality of tension devices may be increased. Even if the number of tension devices is increased, if the tension x at the time of weakening applied to the wire 1 when winding the winding first layer 11 is set to 2 / 5f ≦ x ≦ 3 / 5f, The holding force to the wire 1 is reduced, and the frictional force between each pressing plate and the wire 1 can be reduced.

  As described above, the first layer 11 of the winding 11 is wound by applying the necessary minimum tension capable of correcting the alignment and arrangement to the wire 1, so that the step 30 by the parting line and the sharp burrs are formed on the surface of the insulator 23 as shown in FIG. 5. Even if it exists in 31 or exposed glass fiber 32, it can prevent that wire 1 is pressed against these with strong force, and can prevent deterioration of the insulating film of wire 1 by contact with these. Therefore, an electric motor stator using a resin in which glass fiber is added to the insulator material can be manufactured.

  Further, since the proper proper tension f is applied to the wire 1 in the second and subsequent layers of the winding, it is possible to manufacture an electric motor stator in which the coil placement accuracy is improved and the coil is wound at high density.

  Furthermore, by manufacturing the motor stator using the above-described apparatus, it is possible to provide a high-performance motor stator with high insulation reliability that prevents deterioration of the insulating film of the wire 1.

  Furthermore, a high-performance compressor with high insulation reliability can be provided by incorporating an electric motor having the above-described electric motor stator into the compressor.

  In the above description, the example of the electric motor in which the rotor is disposed inside the stator has been described. However, the present invention is not limited to such a configuration, and the rotor is disposed outside the stator. The same applies to the electric motor arranged in the above.

  1 wire, 5a spring, 5b spring, 7a air cylinder, 7b air cylinder, 8a first fixed pressing plate, 8b second fixed pressing plate, 9a first movable pressing plate, 9b second movable pressing plate, 10 stator core, 11 winding 1 layer, 12 winding 2 layer, 13 winding 3 layer, 14 winding 4 layer, 15 winding 5 layer, 16 winding 6 layer, 17a normal coil arrangement, 17b coil arrangement Deviation, 17c Coil arrangement deviation, 20 winding first layer final coil, 21 back yoke, 22a gap, 22b gap, 23 insulator, 24a-24c teeth, 30 steps, 31 burr, 32 exposed glass fiber.

Claims (3)

A method for manufacturing an electric motor stator that protrudes from a back yoke portion and winds a plurality of layers of a coil while applying tension to a plurality of teeth portions each incorporating an insulator,
When winding the coil of the first layer of the winding that is in direct contact with the insulator, a constant first tension is applied to the coil,
When winding the coils of all layers after the second layer of winding, a constant second tension is applied to the coils,
When the second tension is f, the range of the first tension x is
2 / 5f ≦ x ≦ 3 / 5f
A method for manufacturing an electric motor stator , wherein the tension is constant .   2. The tension device according to claim 1, wherein a plurality of tension devices are mounted to vary the tension applied to the coil, and the tension of the tension device is varied according to command data set in advance when the coil is wound. Method for manufacturing an electric motor stator.   The manufacturing method of the electric motor stator according to claim 1 or 2 using resin which added glass fiber to the material of said insulator.

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