JP2000341889A - Dynamo-electric machine core, manufacture thereof, core segments and dynamo-electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a dynamo-electric machine core, which comprises parts where a high magnetic flux density is required and parts where a high magnetic flux density is not required and whose respective parts are made of suitable different materials in order to improve the utilization of the core materials of the stator of the dynamo-electric machine. SOLUTION: A dynamo-electric machine core has a core back part 22 and a plurality of tooth parts 21. The core back part 22 and the plurality of tooth parts 21 are prepared separately. A plurality of tooth connection parts 221, to which the respective tooth parts 21, are connected are formed on the inner circumference of the core back part 22. The base ends 213 of the tooth parts 21 are attached to the tooth connection parts 221, and the tooth parts 21 are connected to the core back part 22. The core back part 22 consists of a plurality of layered annular coreback layers, which are respectively composed of a plurality of segments 220 lniked with each other to form the annular layers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotating machine core, a method of manufacturing the same, a core back constituting the core, a piece constituting the core back, and a rotating machine using the rotating machine core. In particular, the present invention relates to a technology for realizing a core for a rotating machine having a shape with high material use efficiency.

[0002]

2. Description of the Related Art Rotary machines such as induction motors, synchronous motors, and DC motors, and generators such as induction generators, synchronous generators, and DC generators have, as basic structures, a stator (stator) and a rotor. (Rotor). The stator has a core and a coil. The coil is mounted in a number of slots provided in the core.

[0003] As a method of manufacturing this stator, for example,
For small motors, an inserter system is generally known. For example, as shown in Japanese Patent Application Laid-Open No. Hei 9-135555, a coil wound in a predetermined shape is set in a coil guide called a blade, and this is pushed by a pushing jig called a stripper using hydraulic pressure or the like. The method of inserting into the slot of a core is adopted. For electrical insulation between the coil and the core, in addition to the wire coating, a method is adopted in which slot insulating paper is previously arranged on the inner peripheral surface of the slot of the core, and the coil is inserted therein.
Further, the winding at that time takes a form in which the winding is wound over a plurality of slot teeth of the core by a winding method called distributed winding.

On the other hand, there is a winding method called concentrated winding. This is a method of winding one coil around one tooth. This winding method includes a series winding method in which a wire is wound directly from an inner peripheral portion of a core, and a winding method in Japanese Patent Application Laid-Open No. Hei 6-1054.
As shown in Japanese Patent No. 87, the stator core is divided,
A method of applying a winding to each of the divided cores, welding and joining the core pieces provided with the winding coils, and assembling the core pieces has been adopted as a mainstream.

[0005]

However, the prior art has the following problems. Regarding the material utilization rate of the core, in both the inserter method and the series winding method, since a round stator core is formed from a square material, the material utilization rate is 30 to 40.
% And low. Further, even if the core is divided and the stripping is taken into account, the current state is that the core is about 50 to 60%.

Further, if the magnetic flux density of the core is to be increased, expensive materials will be used in large quantities, and the cost of the rotating machine will increase.

[0007] A first object of the present invention is to provide a technique for increasing the utilization rate of a core material in a stator of a rotating machine.

A second object of the present invention is to provide a technique which makes it possible to configure a portion requiring a high magnetic flux density and a portion not requiring a high magnetic flux density by using respective optimum materials.

[0009]

According to a first aspect of the present invention, there is provided a rotating machine core having a core back portion and a plurality of teeth portions. The portion and the plurality of teeth portions are provided separately, the core back portion has a plurality of teeth connecting portions connecting the respective tooth portions on the inner peripheral side thereof, and the teeth portion has a base end thereof. The core back portion is attached to the teeth connecting portion and connected to the core back portion, and the core back portion has a structure in which a plurality of pieces are continuously arranged in a ring shape and a plurality of layers are stacked. A core for a rotating machine is provided.

According to a second aspect of the present invention, in a rotating machine core having a core back portion and a plurality of teeth portions, the core back portion and the plurality of teeth portions are provided separately from each other, The back portion has a plurality of teeth connecting portions connecting the respective teeth portions on the inner peripheral side thereof, and the teeth portion is connected to the core back portion with its base end attached to the teeth connecting portion, The core back portion has a structure in which blocks in which a plurality of element pieces are stacked are arranged in a row to form a ring, and the rotating machine core is provided.

According to a third aspect of the present invention, in a core for a rotating machine, a core back portion, a plurality of teeth mounted on an inner peripheral side thereof, and a fastening member for fastening the core back portion from outside. And the core back portion has a structure divided at a plurality of locations in the circumferential direction, and the fastening member fastens the core back portion from the outside and separates each of the divided portions of the core back portion. Are provided in the circumferential direction, and a rotating machine core is provided.

According to a fourth aspect of the present invention, in a core for a rotating machine having a core back portion and a plurality of teeth portions, the core back portion and the plurality of teeth portions are provided separately from each other. The back portion has a plurality of teeth connecting portions connecting the respective teeth portions on the inner peripheral side thereof, and the teeth portion is connected to the core back portion with its base end attached to the teeth connecting portion, In addition, the tip of each tooth portion is formed in an arc shape, and in the state of being attached to the core back portion, the core for the rotating machine is configured to sequentially form a circumference with the tip of another adjacent tooth portion. Provided.

According to a fifth aspect of the present invention, in a rotating machine core having a core back portion and a plurality of teeth portions, the core back portion and the plurality of teeth portions are provided separately from each other, The back portion has a plurality of teeth connecting portions connecting the respective teeth portions on the inner peripheral side thereof, and the teeth portion is connected to the core back portion with its base end attached to the teeth connecting portion, In addition, the tip of each tooth portion is formed in a linear shape, and in the state of being attached to the core back portion, a rotating machine core characterized by sequentially forming a polygon with the tips of other adjacent tooth portions. Provided.

According to a sixth aspect of the present invention, the core back used for the rotating machine core has a structure in which a plurality of pieces are continuously arranged in a ring and a plurality of pieces are laminated. A featured core back is provided.

According to a seventh aspect of the present invention, a plurality of layers are laminated to form a core back for constituting a core for a rotating machine. A core back piece is provided which has a form and has a connecting portion for connecting teeth of a rotating machine on a side which is an inner periphery of the core back.

According to an eighth aspect of the present invention, in a method of manufacturing a core for a rotating machine having a core back portion and a tooth portion, a core back portion having a tooth connecting portion to which the tooth portion is connected is formed. While punching the member from the band-shaped member, cutting the member into a length corresponding to the size of the core to be manufactured, stacking the members constituting the core back portion to a desired thickness, and moving the teeth connecting portion around the inner periphery. Bending as a side, forming a core back portion by fixing both ends of the member, and having a connection portion with a tooth connection portion of a member constituting the core back portion, and a state where the tips of the teeth portions are connected. While punching the member from the band-shaped member,
Cut to a length corresponding to the size of the core to be manufactured, and simultaneously or sequentially (in any order) stacking a plurality of members constituting the tooth portion to a desired thickness, with the tip of the tooth portion facing outward. The member is bent in a ring shape, and both ends of the member are fixed to form a teeth assembly. A coil molded body formed in advance is mounted on each tooth portion of the tooth assembly, and an inner periphery of the core back portion is formed. A method for manufacturing a core for a rotating machine, comprising: inserting the teeth assembly into the teeth, attaching the teeth connecting portion to the teeth connecting portion, and fixing each tooth portion to the core back portion. You.

According to a ninth aspect of the present invention, in the method for manufacturing a rotating machine core having a core back portion and a teeth portion, the core back portion is formed in a structure divided at a plurality of circumferential positions. At the same time, the teeth are connected, and the housing having an inner diameter smaller than the outer diameter of the core is expanded by giving a temperature difference, and the core back portion is fitted in the housing, and the housing cools and contracts. This provides a method for manufacturing a core for a rotating machine, wherein a stress is applied in a circumferential direction of the core.

According to a tenth aspect of the present invention, in a method for manufacturing a core for a rotating machine having a core back portion and a tooth portion, the tooth portion and the core back portion are formed by laminating plate members, respectively. A method for manufacturing a core for a rotating machine, characterized in that, after processing the portions to be connected to each other to be thinner than the original plate material, the teeth portion is connected to the core back portion.

According to an eleventh aspect of the present invention, there is provided a rotating machine having a stator formed by winding a preformed coil around the teeth of the rotating machine core. Is done.

According to a twelfth aspect of the present invention, to achieve the second object, in a rotating machine core having a core back portion and a plurality of teeth portions, the teeth portion has a directional characteristic. A core for a rotary machine is provided, wherein the core is formed of a silicon steel sheet and the core back portion is formed of a non-oriented silicon steel sheet.

[0021]

Embodiments of the present invention will be described below with reference to the drawings. In the following embodiments, a core applied to a motor such as an induction motor and a synchronous motor will be described as an example. But,
The present invention is not limited to this. The present invention is applicable to various rotating machines including a generator.

As shown in FIG. 1, the induction motor and the synchronous motor have a stator (stator) 3 and a rotor (rotor) 6 as a basic structure. The stator 3 has a core 2 and a coil 1. In the present invention, a formed coil molded body is used as the coil 1.

As shown in FIG. 2, the core 2 includes a core back portion 22 and a tooth portion 21 protruding inward from the core back portion. Inside the core 2, a space between the teeth 21 serves as a slot 23. The coil molded body 1 is mounted on the teeth 21, and the coil 1 is inserted into the slot 23. In the present invention, a new device has been devised with respect to the core 2 and its manufacturing method. In addition, in connection with the present invention, in addition to the above, a new method of assembling the coil molded body 1 and the stator has been devised.

As shown in FIG. 3, the coil formed body 1 is formed in a state in which the wire is wound in an annular shape while holding the through hole 1a. The through-hole 1a is formed in a cross-sectional shape that can be fitted to the teeth 21. It is desirable that the inside portion of the coil molded body 1 forming the through hole 1a has a shape in which sides are parallel. This is because both sides of the coil mounting portion of the teeth 21 are formed in parallel. Therefore, when the shape of the teeth portion is different, the cross-sectional shape of the through-hole 1a is changed accordingly. Coil compact 1
Has a lead wire 12 for making an electrical connection.

The coil molded body 1 has a shape in which the side surface of the portion accommodated in the slot 23 expands in a fan shape from one end side to the other end side of the through hole 1a. In this case, when the coil forming body 1 is accommodated in the slot 23, the fan-shaped shape is accommodated in a region sandwiched by two adjacent radii of the core 2 passing through the center of each slot 23. Any shape can be used as long as it can be formed. Preferably, the fan-shaped spread coincides with the spread of this region. By doing so, it is possible to accommodate more windings. In addition, it is possible to avoid spatial interference between adjacent coil moldings 1. As a result, when assembling the stator, the contact of the coil molded body 1 can be avoided, and the contact between adjacent coils at the time of assembling, friction, etc.
It is possible to prevent the occurrence of damage, insulation failure, and the like.

The wire constituting the coil formed body 1 is composed of a metal wire and an insulating film for insulating the surface of the metal wire. As the metal wire, for example, copper is generally used. As the insulating film, for example, polyesterimide is used. In the present embodiment, PEW (polyester imide wire) is used.

In this embodiment, FIGS. 1 and 6
As shown in (1), the end on one end side (narrow side of the sector) of the coil molded body 1 is an end face 1c located on the tip 211 side of the teeth, and the other end (side on the wide side of the sector) is the core back. The end face 1d is located on the part 22 side. Here, the end face 1a located on the tooth part tip 211 side has a shape that is receded and inclined toward the inner peripheral side. This is in accordance with the fact that the rear surface of the tip 211 of the tooth portion 21 is inclined. Of course, the end face 1a does not necessarily have to be inclined.

Next, a first embodiment of the core according to the present invention will be described with reference to FIGS. 4, 5, 6, 14 (a) and 1 (a).
This will be described with reference to FIG. FIG. 4 shows an example of a core without a coil attached. FIG. 5 shows an example of a core in a state where the coil molded body is mounted. FIG.
FIG. 14A shows an example of a member constituting a teeth assembly, and FIG. 14B shows a member constituting a core back portion.

As shown in FIG. 4, the core 2 includes a coil back portion 22 and a teeth assembly 21a. The tooth assembly 21a is composed of twelve tooth portions 21 connected at the tips. As is clear from FIG. 4, both the core back portion 22 and the teeth assembly 21a are formed in a ring shape. However, as shown in FIG. 14A and FIG.
A band-shaped plate is used. That is, the members (plates) shown in FIGS. 14A and 14B are laminated until a target thickness is obtained, and the resultant is bent into a ring shape.

As the material of the core 2, a silicon steel plate is usually used, but from the viewpoint of realizing a high magnetic flux density, a material having as large a saturation magnetization as possible is preferable. An example of such a material is a material having anisotropy such that the saturation magnetization is large in a specific direction of the material. An example is a grain-oriented silicon steel sheet. Therefore, when a grain-oriented silicon steel sheet is used in accordance with the direction of the magnetic flux according to the direction of its saturation magnetization, favorable results can be expected. In addition, this grain-oriented silicon steel sheet is characterized in that it is difficult to process and is expensive. Therefore, when using a grain-oriented silicon steel sheet as the material of the core 2, it is necessary to consider these points as well.

In the present invention, since the core back portion 22 and the plurality of teeth portions 21 are separately formed, it is possible to use a material suitable for each. That is, since it is necessary to increase the magnetic flux density in the teeth 21 where the magnetic flux is directed in the radial direction, a material having a large saturation magnetization is used for the teeth 21, and the magnetic flux density is increased in the core back 22 where the magnetic flux is divided in the circumferential direction. Since the core back portion 22 is not required to be formed, it is possible to form the core back portion 22 in such a way that a relatively small material is used. Therefore, in the present embodiment, for the teeth portion 21 where a large magnetic flux density is required, a material having a large saturation magnetization, for example, a grain oriented silicon steel plate is used, and for the core back portion 22 where a large magnetic flux density is not required, Other materials, for example, non-oriented silicon steel sheet, pure iron, soft iron, etc., which are relatively inexpensive and easy to process, are used. This can be applied to other embodiments described later.

As shown in FIG. 14 (b), the core back portion 22 has unit members 22 corresponding to the number of the teeth portions 21.
a are formed in a belt-like shape in which 12 pieces are connected. This is, for example, from a band-shaped member (hoop) not shown, for example,
It can be manufactured by stamping. Unit member 22a
Has a connecting portion 2 of the teeth portion 21 on the side facing the inner peripheral side.
13, a notch 222 for absorbing contraction on the inner peripheral side of the member when the member is bent in a ring shape, and a member bent in a ring shape on the side facing the outer peripheral side. A notch 223 is provided to absorb the elongation of the member on the outer peripheral side when this is done. These are all provided in a cut state. The member constituting the core back portion is fixed in a state where it is bent into a ring shape and both ends are in contact with each other. The fixing can be performed by, for example, welding, caulking, or the like. In the case of caulking, for example, a silicon steel plate is plastically deformed and connected.

As shown in FIG. 14B, when the core back portion 22 is laminated for each unit member 22a,
A caulking portion 229 for caulking with another vertically adjacent unit member 22a is provided. This caulking part 229
Although not shown, the half-blanking process is performed so that a part of the member has a convex shape that protrudes to the lower surface side of the member, for example, and the upper surface side of the member has a concave shape. . Then, at the time of lamination, the convex portion is caulked in a state fitted to the concave portion of another unit member. Note that the relationship of the unevenness in the caulking portion 229 may be upside down.

The teeth connecting portion 221 has a shape which does not come off when it is fitted with a connecting portion 213 on the side of the teeth 21 described later. For this reason, in the present embodiment, the connecting portion 213 on the teeth portion 21 side is provided,
21 is a groove shape.

The tooth assembly 21a is formed by laminating a plurality of members 210 constituting a tooth portion. As shown in FIG. 14 (a), the members 210 constituting the teeth portion are arranged such that the portions to be the teeth portions 21 are alternately arranged so as to face each other, and two sets are formed from one band-shaped member (hoop). Manufactured by stamping. Also in this case, the teeth 21 are manufactured in a united state. Then, it is formed to have a length that becomes a necessary number of teeth portions 21. Such a shape is suitable for mass-producing the teeth 21. In addition, as shown in FIG. 14A, since two sets of members 210 are taken from the belt-shaped member, the material use efficiency can be greatly improved.

The teeth assembly 21a includes the teeth 2
The lateral end 211a of one tip 211 and the lateral end 211a of the tip 211 of the adjacent teeth 21 are connected to each other. With such an articulated structure, the teeth 21 can be handled integrally. For this reason, handling is convenient during manufacture and assembly. There is also an advantage that the strength is increased structurally.

Each tooth 21 has a substantially T-shape.
The rear surface of the protruding portion on the tip side is cut diagonally. Further, a connecting portion 213 for connecting to the core back portion 22 is provided on the base end side of the tooth portion 21 as described above.

Further, each tooth portion 21 has a structure shown in FIG.
As shown in (a), a caulking portion 219 is provided for caulking with another vertically adjacent tooth portion 21 at the time of lamination. Although not shown, the caulking portion 219 is formed by half-blanking so that a part of the member becomes, for example, a convex shape that protrudes to the lower surface side of the member forming the teeth portion 21 and the upper surface side of the member. Is processed so as to have a concave shape. Then, at the time of lamination, the convex portion is caulked in a state fitted to the concave portion of another unit member. In addition, caulking part 2
The relationship of the unevenness in 19 may be upside down.

FIG. 17A shows that the adjacent teeth 21
Are shown in which the tips 211 are separated from each other. In this example, the teeth assembly 21 to which the teeth 21 are connected is shown.
This is formed by cutting the respective tooth portions 21 from a. Of course, it is not limited to this. The cutting can be performed after attaching to the core back member 22 as shown in FIG. Further, as shown in FIG. 17B, the teeth 21 may be punched out one by one from the time of punching and stacked.

Further, the method of assembling the windings of the core 2 of the present invention is different from that of a conventional integrated core.
For this reason, in the core 2 of the present invention, there is no need to provide a gap for inserting a winding. Therefore, even if the teeth 21 are punched out one by one, for example, as shown in FIG.
As shown in (a), a structure in which adjacent lateral tips 211a are in contact with each other when adjacent teeth 21 are inserted into core back 22 can be employed. In this manner, by bringing the adjacent lateral end portions 211a of the teeth portions 21 into contact with each other and abutting each other, it is possible to ensure accuracy on the inner circumferential side of the stator.

The lateral end 211a of the teeth 21
The structure for assembling the core back portion does not depend on the shape of the core back portion. The unit member 22 as shown in FIG.
4A can be applied to a core back portion 22 as shown in FIG. 4 having a structure in which a plurality of connected plate members are processed into an annular shape and laminated. In addition, a structure as shown in FIG. 18C, in which a plurality of pieces 220 are arranged in a ring and a plurality of layers are stacked as shown in FIGS.

Further, as shown in FIG. 25 (b), it is also possible to form the tooth tip 211 straight without forming an arc on the inner circumferential side of the stator. This shape contributes to reducing the cogging torque of the motor.

As described above, in the present invention, the core back portion 2
2 and the teeth portion 21 are divided and formed independently. Each member is formed by laminating members manufactured by punching from a band-shaped plate material. Therefore, it is easy to take out the material, and the utilization efficiency of the material can be increased.

Particularly, in the present embodiment, the teeth 21
As for (2), since the members 210 forming the two sets of teeth are arranged alternately, it is possible to further increase the use efficiency of the material. In the present embodiment, FIG.
As can be seen from FIG.
The useless portion is mainly the cutting margin 21c for separating the two sets.
Therefore, by driving this cutting allowance 21c as much as possible,
For example, a material utilization rate of about 81% can be achieved. In the case of the core back portion 22, since the shape is less wasteful, for example, the material utilization can be 85%. Therefore, according to the present embodiment,
8 for both the teeth and core back
The material utilization rate can be 0% or more. For this reason,
The material utilization can be greatly improved as compared with the conventional structure.

The teeth part 21 and the core back part 22
The teeth 21 having a large magnetic flux density can be made of a material having a large saturation magnetization, while the magnetic flux density is formed in a core back portion 22 having a relatively small magnetic flux density as compared with the teeth 21. Since the saturation magnetization may be smaller than that of the teeth portion 21, it is easy to process and an inexpensive material can be used.

Next, the above-described coil formed body will be described with reference to FIGS. 7 to 9 show a molding die and a molding process using the molding die. 10 and 11 show molding conditions. 12 and 13 show the compression state of the winding.

FIG. 7 shows a coil forming die used for forming a coil formed body. FIG. 7 shows a state after the coil has already been compression-molded.

The mold shown in FIG. 7 includes a bobbin 15a for winding a wire constituting a coil, and a pressing mold 15b for pressing a group of wires 11 wound on the bobbin 15a.
5c and 15d. For the molding, a pressing device (not shown) and a control device for controlling the pressing are used. As the pressurizing source, for example, hydraulic pressure or pneumatic pressure is used.

The pressing die 15b presses the side surface of the coil winding 11 group, that is, the portion to be the side surface 1b of the coil molded body 1. The pressing dies 15 c and 15 d press the end surfaces of the group of coil windings 11, that is, the portions that become the end surfaces 1 c of the coil molded body 1. In this case, the pressing die 15c presses in a direction orthogonal to the pressing die 15b. For this reason,
The lower end surface of the pressing die 15d and the upper end surface of the pressing die 15c are brought into contact with each other at an angle.
A component force in the direction perpendicular to the pressing force of 5d is taken out, and the pressing mold 15c is pressed in the lateral direction.
By doing so, there is an advantage that pressing can be performed from the same direction by a common pressure source.

Here, the forming conditions of the coil formed body will be described. In order to simplify the description, it is assumed that the end surface 1c of the coil molded body 1 is not inclined.

As shown in FIG. 8, the wire rod 1 is attached to the bobbin 15a.
1 is wound, and the pressing dies 15b, 15
Pressed by c and 15d. Thereby, as shown in FIG. 9, the gap between the wires 11 is crushed,
The wire 11 itself is deformed and possibly compressed to form the coil molded body 1. As shown in FIG. 9, after the molding, the entire shape is maintained by the deformation of the wire 11. In addition, at the time of molding, the insulating film (not shown) covering each wire also deforms with the deformation of the wire itself.
However, as shown in FIG. 10 to be described later, according to the experiment by the present inventors, the insulating coating of the wire was not broken by the molding.

The shape of the mold is appropriately selected according to the shape of the coil formed body. For example, the mold shown in FIG.
As described above, it is used when molding a structure having an end surface on one end side of the coil molded body 1 as an inclined surface. On the other hand, the molds shown in FIGS. 8 and 9 are used in a case where the end surface on one end side of the coil molded body 1 is not formed as an inclined surface.

Next, the outline of the shape change of the coil molded body will be described with reference to FIGS. 10, 11 and 12. FIG.
As shown in FIG. 12, the coil cross-sectional dimension in a state where the wire 11 is wound is clearly different from the cross-sectional dimension of the coil molded body 1 after molding. That is, assuming that the diameter of the wire 11 is d, the dimension D1 in the horizontal direction of the drawing is ｛d + √3d / 2 ×
(The number of stages -1)}. The vertical dimension L1 is (d
× number). The coil cross-sectional area is (D1 × L1). Therefore, the cross-sectional dimension in the winding state cannot be geometrically smaller than this cross-sectional area.

In the present invention, the coil cross-sectional area is made smaller than that in the wound state by adding molding to the slot insertion portion of the coil after winding. If the cross-sectional areas of the wires themselves are equivalent, by adding molding, the coil cross-sectional area (D2 × L2) after forming becomes smaller than the coil cross-sectional area (D1 × L1) after winding. Further, if the cross-sectional area of the wire itself is reduced by compression, the cross-sectional area of the entire coil cross section (D2 × L
2) is about 80% of the original. Thus, the present invention changes the cross-sectional area of the coil by adding the forming step from the state of the winding.

That is, in the coil molded body 1 of the present invention, when the diameter of the wire is d, the number of windings arranged in the radial direction of the core is m, and the number of windings arranged in the tangential direction of the core is n, the wire is formed in the slot. The cross-sectional area S0 in a certain cross section in the orderly wound state is represented by S0 = {d + {3d / 2 × (n-1)} × (d
× m), so that the cross-sectional area Sp of the portion accommodated in the slot in the cross-section at the same portion is (Sp <S0).

FIG. 10 shows the relationship between the cross-sectional dimension D2 and the load during molding. FIG. 11 shows a graph of this relationship. In these relations, the load is represented by a load applied per 480 mm ² .
Also, the case where a wire having a wire diameter of 1.2 mm is used is shown. As shown in FIGS. 10 and 11, when the pressing force during molding is increased, the cross-sectional dimension is reduced. However, when the load is a certain level or more, for example, 6 tons or more, there is no significant change.

The number of pinholes shown in FIG. 10 means the number of broken portions of the insulating film of the wire. Usually, it is an inspection method for checking the number of places where electricity leaks when an electric wire is immersed in an electrolytic solution. The inspection result is represented by the number. In the present embodiment, in the range shown in FIG. 10, the number of pinholes is 0 even when the load increases. Therefore, this shows that the insulating film was not damaged by the molding.

The effect of forming a coil as in the present invention will be described with reference to FIG. FIG.
(A) to FIG. 13 (e) show a winding state around the teeth portion.

In general, in the case of winding into a polygonal shape having corners, such as a mold, a bobbin, and a tooth portion, FIG.
As shown in (a), the wire of the coil 1 has a mold at a corner,
Close contact with the winding base material such as bobbin and teeth 21 (Fig. 1
3 (b)), the wire is wound in a state where the clearance is most widened from the winding base material at the center of the side. As shown in the BB cross section of FIG. 13C, it can be seen that there is a considerable gap with the base material at the center of the side. If the coil is assembled as a motor stator in this state, the space will decrease due to this gap, and the motor performance will decrease. Therefore, as described above, by applying a molding force to the side portion of the coil in the wound state after the winding, as shown in FIG.
As shown in FIG. 3 (d) and FIG. 13 (e), the coil has a shape in which the wire is in close contact with the base material also at the side of the coil. Thus, the motor stator can be assembled in a state where the space factor is high.

Even with the structure as shown in FIG. 13E, the space factor can be improved as compared with the case where no molding is performed. In addition to simply compressing the side portions of the coil, the cross-sectional shape of the slot insertion portion is formed so as to match the shape shown in FIG. 6, that is, the internal shape of the half portion of the slot 23. can do. This is preferable because the space factor can be further improved. When assembling the coil, the coil 1 is inserted from the outer peripheral side of the teeth 21. At that time, it is necessary to shape the coil so that it can be inserted into adjacent coils without interference. As a result, it becomes possible for the coil to enter the cross-sectional area of the slot without any excess,
High space factor can be realized. The cross-sectional shape of the coil in the slot is similar to the cross-sectional shape of the slot. This is also an advantage when the core is divided. When winding the teeth with an insulating material such as a bobbin, do not perform wire cross-section shaping, even in the case of low space factor coils, since the coil cross-section is similar to the slot shape, there is room for winding. Wires can be formed, which has the effect of improving the insulation degradation life and the like.

Next, the assembly of the stator of the rotating machine will be described with reference to FIGS. 3, 5, 6, 7, 14, and 15. The assembling is not limited to the method described below. However, according to the following method, there is an advantage that the handling of each member is easy, so that automation is easy.

First, the coil wound on the bobbin 15a is pressed by using pressing dies 15a, 15b and 15c as shown in FIG. 7, and the coil winding is compression-molded.
Thus, a coil molded body 1 as shown in FIG. 3 is obtained.

On the other hand, as shown in FIGS. 14 (a) and 14 (b), a member serving as the teeth assembly 21a and a member serving as the core back portion 22 are punched out of the belt-shaped member. And the like. The production of these members is not limited to punching. It may be performed by another method. Thereafter, the members 21 constituting the teeth portion
The necessary number of members to be the core back part 22 are stacked on the zero. At the time of lamination, after each member is overlaid, caulking is performed by applying pressure in the lamination direction. Thus, the caulked portion 219 and the caulked portion 229 are firmly connected. Thereafter, the core back portion 22 is bent. That is, each of them is bent so as to form a ring. After bending, both ends are fixed by a method such as welding or caulking. Thus, the core back portion 22 and the teeth assembly 21a are manufactured.

Next, as shown in FIGS. 15A and 15B, the coil molded body 1 is fitted into each tooth portion 21 of the tooth assembly 21a. That is, the through hole 1a of the coil forming body 1 and the teeth 21 are fitted. At this time, each coil molded body 1 is fitted to the teeth portion 21 such that the end surface 1a faces the inner peripheral side. This state is shown in FIG.

Next, as shown in FIG. 15A, the teeth assembly 21a on which the coil formed body 1 is mounted is fitted to the inner periphery of the core back portion 22. At this time, circumferential positioning is performed so that the teeth connecting portion 221 of the core back portion 22 and the connecting portion 213 of the teeth portion 21 are fitted. When assembled in this manner, a stator as shown in FIG. 5 is obtained together with the formation of the core.

As described above, in the present embodiment, the coil molded body 1 is mounted on the tooth assembly 21a by pushing each tooth portion 21 into the through-hole 1a of the coil molded body 1 so as to be inserted. Therefore, the coil can be mounted on the core very easily. In addition, since the coil molded body 1 has a fixed shape, a special jig for preventing the coil from being disturbed upon mounting is not required. Further, since the coil can be mounted at a high density on the coil molded body 1 itself,
Occupancy rate in the occupancy can be increased.

The stator having the above-described structure can increase the material utilization rate while maintaining a high space factor. A structure which can further improve the performance of the stator having such a structure will be described with reference to FIG.

The examples shown in FIGS. 16 (a) to 16 (g) show various forms relating to the connecting portion between the core back portion and the teeth portion. These forms correspond to the connecting portion 2 of the teeth portion 21.
This is an example of eliminating a gap that may be generated between the connection portion 13 and the connecting portion 221 of the core back portion 22.

FIG. 16 (a) shows that the core of the core back portion 22 is bent along the extension of the teeth portion 21 and the coil molded body and the core 2 are assembled. When assembling the housing 4 as shown in FIG.
, The bent portion is further compressed, and the joint between the core back portion 22 and the teeth portion 21 is tightened. Therefore, the cuts 224 are formed in the core back member 2.
2 is provided in advance. The form of the cut 224 is variously possible. FIG. 16A shows an example of a deep V-shaped cut.

The cut 224 is provided on the inner peripheral side of the core back portion 22 so that the circumferential length of the connecting portion 221 of the core back portion 22 can be increased or decreased. Thereby, the connecting portion 213 of the teeth portion 21 is connected to the connecting portion 22 of the core back portion 22.
1, and by applying a force to shorten the circumferential length of the connecting portion 213, the connecting portion 213 of the teeth portion 21 is connected to the connecting portion 22 of the core back portion 22.
1 can be reliably and firmly connected. Also,
The notch 224 also functions as a weak part against the stress applied during assembly. Thereby, it becomes easy to bend the core back portion 22.

FIG. 16B shows a connection portion 213 of the teeth portion 21 with the core back portion 22 and the core back portion 2.
This is an example in which a connecting portion 221 to the second tooth portion 21 is tapered like a V-shape. In this example,
When the housing is mounted on the outer peripheral portion of the core back portion 22, the connecting portion 213 acts so as to be pressed by the slope of the connecting portion 221. At this time, as described above, the teeth portion 21 has a lateral tip portion abutting on other lateral tip portions adjacent to each other on the tip side, so that the teeth portion 21 cannot be displaced to the inner peripheral side. is there. Therefore, the teeth part 2
Numeral 1 is a force that acts in the circumferential direction at its own tip and a force that acts on the connecting portion 213, and is firmly held in the core back 22. As described above, this connection form employs a structure in which the connection portion is further compressed by press-fitting and shrink-fitting the housing and the core, and the connection portion 213 between the core back portion 22 and the teeth portion 21 is tightened.

In FIG. 16C, the connecting portion 221 of the core back portion 22 has a shape cut long in the circumferential direction as shown in the figure. Thus, when the connecting portion (not shown) of the teeth portion 21 is assembled by utilizing the resiliency of the plate material constituting the core back portion 22, the teeth connecting portion 221 of the core back portion 22 is elastically deformed, The structure is such that the fastening force remains in the connecting portion even after the connection.

FIG. 16D shows a structure in which the core back 22 and the teeth 21 are connected via another member 24 connecting the core back 22 and the teeth 21. For this purpose, the core back portion 22 is provided with a notch 225 in the axial direction. On the other hand, a similar notch 214 is provided in the connecting portion 213 of the tooth portion 21. The member 24 is formed by connecting the teeth 21 to the core back 22.
5 and 214 have a planar shape penetrating into a hole-shaped space. Assembling is performed by adding the teeth part 2 to the core back part 22.
1 are connected to each other, and
Can be performed. With such a structure, the connection between the core back portion 22 and the teeth portion 21 can be strengthened.

FIGS. 16 (e) and 16 (f) both use a joining method called a ball expanding method. That is, the hole 226 is provided in the core back portion 22 at a position sandwiching the connection portion 213 of the tooth portion 21 or the hole 215 is provided in the connection portion of the tooth portion 21. With each connected, a slightly larger ball and shaft are passed through the holes so as to widen the holes. Thereby, the core back part 22 or the teeth part 21 is plastically deformed,
Get the binding power.

FIG. 16 (g) shows the shape of the teeth portion 21 and the core back portion 22 in the form of a dovetail groove structure as in the above-described embodiment, between the dovetail (213) and the dovetail groove (221). This is a structure for driving and positioning a wedge 26 commonly called a razor.

By using the example as described above, at the connecting portion between the core back portion and the teeth portion,
The gap can be reduced as much as possible. For this reason, vibration noise can be further suppressed. As a result, it is possible to obtain a stator core with reduced influence on the life and characteristics.

Next, a second embodiment of the core according to the present invention will be described with reference to FIGS. The present embodiment relates to a rotating machine core including a core back portion and a plurality of teeth portions, wherein the core back portion and the plurality of teeth portions are provided separately.

In the present embodiment, the core back portion 22
A piece 220 as shown in FIG.
As shown in FIG. 18C, a plurality of layers are arranged in a ring in a row, and a plurality of layers are stacked as shown in FIG. As shown in FIG. 18A, the core back portion 22 in the present embodiment has a plurality of teeth connecting portions 221a that connect the teeth portions 21 on the inner peripheral side. Further, teeth connecting portions 221b are also provided at portions located on the inner peripheral side of the core at both ends.

The teeth connecting portion 221a is connected to the teeth portion 2
It is provided in a form that fits with the connection portion 213 on the one side. In the present embodiment, it has a shape in a form of a dovetailed groove structure.
As shown in FIG. 18A, the connecting portion 221a
A notch 228a is provided. The element piece 220 is also provided with a shallow cut 228b on the outer peripheral side of the position where the cut 228a is provided. The notch 228a is cut out in a V-shape at an angle at which the edges of the notch 228a do not overlap in a state where the element piece 220 is bent. On the other hand, the notch 228b is for expanding and facilitating the bending when the piece 220 is bent. Therefore, any other shape may be used as long as it has such a function.

When the teeth connecting portions 221b at both ends are adjacent to each other piece 220, each of the teeth connecting portions 221b of the tooth portion 21 is similar to the tooth connecting portion 221a.
13 is formed in a shape that forms a dovetail structure that can be fitted with the groove 13. Further, the end face (divided end 220b) provided with the connecting portion 221b has a slanted inner peripheral side so as to form a gap, for example, a V-shaped gap when connected to the adjacent piece 220. Has been cut off.

The core of the present embodiment is formed by
0 are laminated. In the present embodiment, first, FIG.
A piece as shown in FIG.
As shown in (b), a bending process for bending is performed. Then, using a plurality of pieces 220 processed in such a manner,
As shown in FIG. 18C, a plurality of pieces 220 are arranged in a row in a row, and a plurality of the pieces 220 are stacked to form the core back portion 22.

The piece 220 is provided with a caulking portion 229 for caulking when laminating. Therefore, after all the pieces 220 are stacked, the entire body is pressurized to caulk the caulking part 229.

Element 220 Constituting Core Back Section 22
As described above, a material having a large saturation magnetization is preferable. For example, the above-described directional silicon steel sheet or the like is used.
On the other hand, as the piece 220 used in the present embodiment, as the teeth 21, for example, as shown in FIG. 17B, a member obtained by stacking members obtained by individually punching plate materials is used. The caulking portion 2 is also used for the teeth portion 21.
Caulking is performed by 19. As described above, for example, a non-oriented silicon steel sheet is used as the material.

Next, a method of manufacturing a core according to the present embodiment will be described.

In the present embodiment, the piece 220 constituting the core back portion 22 is formed into a punched shape as shown in FIG.
1 is punched out in a bent shape, and bent as shown in FIG. Then, as shown in FIG. 3C, the core back portion 22 is formed by lamination. The base end 213 of the tooth part 21 is attached to the tooth connecting part 221 of the core back part 22. This core back part 2
2, the tooth part 21 incorporating the coil 1 is press-fitted.
Obtain the stator.

Here, the teeth portion 21 is attached to the teeth connecting portion 221 of the core back portion 22 at the base end 21 thereof.
3 is fitted. The fitting can be performed, for example, by fitting the base end 213 into the tooth connecting portion 221 along the axial direction of the core and relatively displacing the tooth portion 21 in the axial direction. Thus, the teeth 21
FIG. 18D shows a state in which is attached to the core back portion 22. Note that FIG. 18D does not show a state in which the coil is mounted, but actually, the teeth portion 21 is mounted on the core back portion 22 after the coil molded body 1 is mounted thereon.

In order to hold this stator core, it is mounted on an outer frame called a housing. As the housing, for example, a cylinder is used. The material is, for example, iron,
Aluminum or the like is used. The thickness of the cylinder is, for example,
Those having a size of about 2 to 10 mm are used.

The core back 22 is assembled to the housing 4 by press fitting, shrink fitting, or the like. In the case of shrink fitting, the cylindrical housing 4 is heated and expanded. In this state, as shown in FIG. 19A, the core back portion 22 on which the coil and the tooth portion are mounted is inserted into the housing 4. Thereafter, the temperature of the housing 4 decreases and contracts, and a stress due to the contraction acts on the core back portion 22 inside. That is, the core back portion 22 includes
A stress acts along the radial direction and toward the center.
For this reason, the core back part 21 contracts so that the radius becomes small as a whole. Specifically, cuts, gaps, and the like are closed. This state is shown in FIG. That is, the notch 228a is closed, and the gap at the end (the divided end 220b) of each piece 220 is eliminated. Further, the lateral ends 211a of the tips 211 of the teeth 21 and the lateral ends 211a of the tips 211 of the adjacent teeth 21 are in contact with each other.

As described above, in the present embodiment, FIG.
As shown in (b), by shrink fitting of the housing 4,
The core back part 22 is compressed. Further, since the stator of the present embodiment is constituted by the element pieces 220, the stator has a structure in which the core back portion 22 is divided into a plurality. As a result, when assembled to the housing, split ends 220b are formed at each end of the continuous piece. Stress is generated so as to reduce the gap between the divided ends 220b and the above-mentioned cuts. For example, when the stator outer diameter after assembly is φ100.5 mm, the housing for shrink fitting has an inner diameter d =
When the diameter is 100 mm and the material is aluminum, the expansion coefficient is α =
Since it is 23.1 × 10 ^-6 , the temperature difference t from normal temperature t = 30
When the temperature is increased by 0 ° C., the expansion amount becomes δ = αdt = 0.693 mm. Therefore, the inner diameter of the housing is 100.693m
m, which is larger than the stator outer diameter. By assembling in this dimensional relationship and cooling the housing, the expanded housing inner diameter is reduced, and the stator outer diameter is tightened.

The amount of tightening at this time is determined by the thickness and material of the housing and the stator. For example, in the above-described example, the final housing inner diameter is 100.2 mm. As a result, the outer diameter of the stator is
mm. Therefore, 0.3 mm from the dimension after assembly
It can be said that the outer diameter shrank.

As a result, the divided ends 220 of the stator
The gap b becomes smaller by 0.3π = 0.942 mm on the circumference. Accordingly, if there are 12 gaps and cuts as shown in FIG.
It is possible to close the 78 mm gap.

Further, in this structure, the teeth portion is divided into the divided end portion 220b of the core back portion 22 and the cut portion 228a.
, The gap of the core back portion 22 can be narrowed, so that the gap for assembling the teeth portion can be simultaneously tightened. For this reason, it is possible to increase the mechanical strength of the teeth portion and the core back portion.

As a method of tightening the housing, in addition to shrink fitting of the housing, there are a method of tightening with a sleeve and a method of tightening with a steel band. The sleeve is a method of assembling a cylinder made of stainless steel, iron, or the like having a thickness of 0.2 to 0.3 mm, and has an advantage that the outer diameter of the motor can be reduced. Further, a method in which the steel band 7 as shown in FIG. 20 is wound and fastened by fastening such as welding or caulking in a state where the band is fastened is also conceivable.

Further, as shown in FIGS. 21 (a) and 21 (b), the outer peripheral portion of the divided end portion 220b of the core back portion 22 is welded in a state of being tightened from the outer periphery, and the tightened state is maintained. be able to. As shown in FIG. 21 (a), in the present embodiment, in addition to the divided end 220b, the notch 2
28b is also welded for reinforcement. The welding for the notch 228b can be omitted. In FIG. 21A, the notation of coils is omitted.

Further, as another method, there is a method of fastening a core by a mold shown in FIG. This method is a technique of wrapping a coil end portion of a stator core with a resin material. As shown in FIG. 22 (a), the wound stator core 2 is set in a mold 9 and a resin 10 is poured into both ends (coil end portions) to be molded. At this time, the resin 10 is poured in a state where the core 2 is tightened by the mold 9, and the groove provided inside the slot portion of the core 2 and on the outer periphery of the core is filled with the resin. Thereby, the stator core 2 is fastened. As a result, FIG.
As shown in (b), the core can be fixed while keeping the clearance of the core back portion coupling portion reduced by tightening. According to this method, the core can be fastened without increasing the outer peripheral portion of the core.

In any of the above-described methods, the gap between the core divided portions is reduced by having the above-described divided structure, and the coupling strength with the teeth portion is obtained.

In the embodiment described above, the material can be used efficiently for the same reason as described above.

Further, the element piece 220 is not limited to the above-described embodiment. For example, as another form, the shape shown in FIG. 23 is possible, and each has an advantage.

The shape shown in FIG. 23 (a) is an example in which the core back portion 22 is punched in a shape after being bent in advance. In this example, lamination is performed without performing bending. In this case, the mechanical strength in the circumferential direction can be increased. This is a method by which the decrease in magnetic resistance can be halved.

The shapes shown in FIGS. 23 (b) and 23 (c) are punched out in a shape after bending as in the example shown in FIG. 23 (a). In these examples, a shape in which slit grooves 228c and 228d are inserted into the joint portion at the time of punching is formed in order to provide a stress concentration portion for reducing the circumferential length by shrink fitting stress or the like from the outer peripheral portion after assembly. According to this shape, the stress generated by shrink fitting or the like, that is, the stress that reduces the gap as described above, can minimize the bonding strength with the teeth portion and minimize the gap. There is a difference in this point from the shape of FIG.

The shapes shown in FIG. 23 (d) and FIG. 23 (e) are formed by punching out the shape after bending at the time of punching press. In this example, the joint portion with the teeth portion is stamped and thinned to form thin portions 228e and 228f.
To form As a result, the parts that are weak against stress, that is, the stress concentration parts, are actively provided, and the stress such as shrink fitting, that is, the stress that reduces the gap, realizes the joint strength with the teeth part, minimizing the gap It is made possible.

Further, all of these methods are shown in FIG.
As shown in (f), the core back portion 3 may be connected, and a shape in which a plurality of core back portions are connected may be employed.

The above-described piece 220 is, for example, as shown in FIG.
As shown in (b), it can be provided in a series from a strip. Further, as shown in FIG. 23 (g), it can be formed so as to be individually punched from the belt-shaped material.

Next, a third embodiment of the present invention will be described.
This will be described with reference to FIGS. 24 (a) and 24 (b).
This embodiment is basically the same as the above-described embodiment, except that the mode of lamination of the element pieces 220 is different. For example, the same configuration can be adopted in mounting a coil, assembling a housing, manufacturing a rotating machine, and the like. Therefore, the description will focus on the differences.

The embodiment shown in FIG. 24A relates to a rotating machine core having a core back portion and a plurality of teeth portions. In the present embodiment, similarly to the other embodiments described above, the core back portion 22 and the plurality of teeth portions 2
1 is provided separately. The core back portion 22 has a plurality of teeth connecting portions 221a and 221b connecting the teeth portions 21 on the inner peripheral side. The teeth portion 21 has a base end 213 having the teeth connecting portion 221.
a or 221b and connected to the core back portion 22.

Here, the core back portion 22 has a structure in which a plurality of pieces 220 are arranged in a row in a row and a plurality of layers are laminated. Further, the core back portion 22 is arranged such that the element pieces 220 are shifted in the circumferential direction in units of slot pitch between adjacent layers. At the time of laminating,
At 9, caulking is performed. With such a configuration, the teeth connecting portions 221a and 221b are arranged at equal pitches (slot pitches) on the inner peripheral edge of the core, as in the above-described embodiment. These teeth connecting portions 221a and 221b extend along the axial direction of the core.

Next, the embodiment shown in FIG. 24 (b) relates to a rotating machine core having a core back portion and a plurality of teeth portions, similarly to FIG. 24 (b). In the present embodiment, the core back portion 22 has a structure in which blocks 220a in which a plurality of pieces 220 are stacked are arranged in a row in a row and the blocks 220a are stacked in a plurality of layers. Other configurations are the same as those in FIG.

The core back unit 22 is provided with the block 220
a are arranged so as to be shifted in the circumferential direction by a slot pitch unit between adjacent layers.

In the present embodiment, in addition to the illustrated piece 220, the above-described various pieces shown in FIG. 23 can be used.

Further, in this embodiment, the teeth portions can be connected by using the other embodiments described above. In addition, for example, FIG.
A tooth portion 21 having a form as shown in FIG. That is, as shown in FIG. 27 (a), the sheet is individually punched from the band-shaped plate, and
Fig. 27 obtained by laminating and caulking the plates
The teeth 21 shown in FIG.

[0111] When the various element shapes shown in FIGS. 23A to 23F are used, the material utilization rate is improved. For example, as shown in FIG. 23 (g), when the piece 220 is punched from a plate material, the material utilization rate is 70% or more. In addition, in the form shown in FIG.
In the case of individually punching 1 from a band-shaped plate, for example,
It is possible to achieve a material utilization of 70% or more.

Next, a modification of the structure of the joint portion between the teeth portion and the core back portion will be described with reference to FIG. 26 (a), (b) and (c) show the presence (the base end 213) and the presence groove (the teeth connecting portion 22).
This is a combination with 1).

FIG. 26 (a) shows that the corners of the dovetail and the dovetail groove are rounded. Also, FIG.
(B) shows the shape of the dovetail 213 and the dovetail groove which are mutually inclined. FIG. 26 (c) has a connection portion similar to that of FIG. 26 (b), and has a shape in which the core back portion has at least two cuts 228 (or thin portions). Tightening stress is applied from both sides around the notch, thin wall, etc.
1 has a structure that is tightened by the stress.

Next, another embodiment of the laminated structure of the core will be described with reference to FIG. In the first embodiment described above, as a material forming the core back portion 22, a shape in which a material punched in a linear shape is bent and wound in order to increase the material utilization rate of the core is proposed. However, the core back portion 22 does not necessarily need to use a material connected in series. Therefore, as described above, the element pieces are punched out, arranged so as to be continuous along the circumference of the core back portion, and laminated.
Alternatively, a block may be formed by stacking a plurality of pieces, and the blocks may be stacked along the circumference of the core back portion. By using the element pieces as described above to form the core back portion 220, the die for punching is small and the punching processing force is small, so that the setup change of the model exchange can be easily performed. The effect can be expected.

In the present application, a more preferable embodiment is proposed when stacking the element pieces. Referring to FIGS. 28 and 29, FIG. 28 shows a method of laminating laminated steel sheets. The laminated steel sheet is a method of combining upper and lower plates with a half-blanked portion such as a HAC caulking or a dowel caulking. However, the insulation between the plates is broken,
A problem that a current loop or the like occurs may occur.

The caulking method shown in FIG. 28A is an assembling method in which the pieces 220 are assembled alternately one by one at a pitch of one slot as described with reference to FIG. In the present embodiment, two or more caulking portions 229 are provided on the element piece 220, and one caulking portion 229a is provided.
Is formed by half-blanking to provide a convex portion 229c, and the other caulking portion 229b is machined into a fully-blanked state to form a through hole 229d. The caulking portions 229a and 229b are provided at intervals of one slot pitch. Therefore, when the upper and lower pieces 220 are shifted by one slot pitch in the circumferential direction, caulking can be performed at the positions shifted by one slot pitch.

Here, as shown in FIG. 24, in the case where all are in a half-punched state, the crimping mode is the same even if the upper and lower segments 220 are shifted. However, FIG.
In the example shown in (a) to FIG. 29 (d), the pieces 220 are half-opened by stacking the pieces 220 alternately.
c is connected to the through hole 229d of the lower plate, and is not connected to the through hole 229d of the upper plate. On the other hand, the portion in the fully-extracted state is inserted and coupled with the convex portion 229c of the upper plate, and there is no coupling with the lower plate.

As a result, the loop through which the current flows can be interrupted, and the characteristics of the motor can be improved.

FIGS. 29 (a) and 29 (b) show a laminated structure of a portion of the teeth portion 21 which is connected to the teeth connecting portion of the core back portion. When laminating a core having a notch, a groove, a thin portion, or the like described with reference to FIG. 23, there is a possibility that the metal surface may make electrical contact due to burrs or the like generated when processing the portion. Therefore, the electric contact is obstructed by shifting the portion between the upper and lower sides. Therefore, in the connecting portion as shown in FIG. 29A, as shown in FIG. 29B, the thickness of the base end 213 of the teeth portion 21 in FIG. To make the thickness smaller than the plate thickness.
This makes it possible to avoid electrical contact between the upper and lower plates due to processing burrs and the like at the connection portion such as the core back portion and the teeth portion. For this reason, the caulking part 22
9, it is possible to improve the efficiency of the motor itself, including the reduction of the contact portion.

Note that the thinning is not limited to the base end portion 213 of the teeth portion 21. For example, the core back portion 22
The teeth connecting portion 221 may be configured to be thinned.

Next, the present invention can be applied to each of the above embodiments.
An improvement measure will be described with reference to FIG. That is,
As shown in FIGS. 30 (a) and 30 (b), the thickness Lc of the core back portion and the thickness Lt of the teeth portion are crushed by means of a press or the like to form the same. This can be expected to prevent displacement in the thickness direction after assembly.

As another problem related to the present invention,
There is a problem with the coil, so it should be pointed out.

First, in the coil inserter system, a wound coil is inserted by utilizing a gap in a slot. Therefore, if a stator coil is inserted by an inserter after winding, a space factor (core slot) is required. (The ratio of the cross-sectional area of the wire to the cross-sectional area of the wire) cannot be large. At present, the space factor is limited to 60 to 65%. Second, even in the concentrated winding method, in the series winding method, the wire is inserted by using the gap of the core slot as in the inserter method, so that the space factor is not very high (about 60%). In addition, even if the method of dividing and winding the core is adopted, the space factor cannot be set high due to clearances at the time of assembling the core, uneven winding between wires, and dimensional relationships such as considering interference of adjacent coils. In the situation.

In the above-described embodiments, the problem of improving the space factor of the stator windings in the rotating machine is solved by using a preformed coil formed body. That is, by changing the sectional shape of the coil, the sectional dimensional accuracy can be increased, and the space factor can be improved. Thereby, the efficiency of the rotating machine can be improved. In addition, the core of the rotating machine can be reduced in size by reducing the size of the core for the improvement in efficiency, and the number of conductors used can be reduced, so that the material cost can be reduced.

[0125]

According to the present invention, there is an effect of increasing the utilization rate of the iron core material in the stator of the rotating machine. Further, according to the present invention, it is possible to configure a portion requiring high magnetic flux density and a portion not requiring high magnetic flux density by using respective optimum materials.

Further, from the viewpoint of material utilization, it is possible to greatly reduce material costs. As a result, the rotating machine,
In particular, since the electric motor is a key part of the set product,
A compact, lightweight and low-cost set product using an electric motor can be realized.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view showing a general structure of a motor to which the present invention is applied.

FIG. 2 is a perspective view showing a general structure of a motor stator to which the present invention is applied.

FIG. 3 is a perspective view showing an example of a coil formed body used in the rotating machine of the present invention.

FIG. 4 is a plan view showing an example of a core according to the present invention.

FIG. 5 is an explanatory view showing a mounting position of a coil formed body on a core according to the present invention.

FIG. 6 is a partial cross-sectional view showing a mounted state of a coil molded body to a tooth portion used in the present invention.

FIG. 7 is an explanatory view showing a forming state of a coil formed body used in the rotating machine of the present invention.

FIG. 8 is an explanatory view showing a state before molding in a coil molded body having another shape.

FIG. 9 is an explanatory diagram showing a cross-sectional forming dimension relationship after forming in a coil formed body used in the rotating machine of the present invention.

FIG. 10 is a table showing a relationship between an excessive load, a forming dimension, and a pinhole when forming a coil formed body used in the rotating machine of the present invention.

FIG. 11 is a graph showing a relationship between an excess load and a forming dimension when forming a coil formed body used in the rotating machine of the present invention.

FIG. 12 is an explanatory diagram showing a change in a cross-sectional area of a coil winding used in the rotating machine of the present invention before and after forming.

FIG. 13 (a) is an explanatory view showing a state in which a general coil winding is mounted on a teeth portion, and FIG.
13A is a cross-sectional view, FIG. 13C is a BB cross-sectional view, and FIG.
(D) is an explanatory view showing the winding state after the coil is formed, FIG.
(E) is the AA sectional view.

FIG. 14A is a plan view showing a state where members constituting the teeth assembly are punched out of a belt-shaped member;
(B) is a top view showing the state where the member which constitutes the core back part was punched out of the belt-like member.

FIG. 15A is a perspective view showing a state in which a stator is assembled by a coil forming body and a core of the present invention, and FIG.
5B is an explanatory view showing a state where a coil is mounted on the teeth assembly, and FIG. 15C is an explanatory view showing a state where the coil is mounted on the teeth assembly.

FIG. 16A is a partial plan view showing another first embodiment of the connection relationship between the core back portion and the teeth portion, and FIG. 16B is a connection diagram between the core back portion and the teeth portion. 16C is a partial plan view showing another second embodiment of the relationship, FIG. 16C is a partial plan view showing another third embodiment of the connection relationship between the core back portion and the teeth portion, and FIG. FIG. 16E is a partial plan view showing another fourth form of the connection relationship between the back portion and the teeth portion, and FIG. 16E is a partial plan view showing another fifth form of the connection relationship between the core back portion and the teeth portion. FIG.
(F), Partial plan view showing another sixth embodiment of the connection relationship between the core back portion and the teeth portion, FIG. 16 (g), another seventh embodiment of the connection relationship between the core back portion and the teeth portion. FIG.

FIG. 17 (a) is a plan view of a core in which the tips of adjacent teeth are separated from each other, and FIG.
FIG. 7B is a perspective view showing the stacked teeth portions.

18A is a plan view showing an example of a piece constituting a core back portion, FIG. 18B is a plan view showing a state in which the piece is bent, and FIG. FIG. 18 is a perspective view showing a state in which pieces are laminated to form a core back portion.
(D) is a plan view showing a shape in which the core back portion and the teeth portion are assembled.

FIG. 19A is an explanatory view showing a state in which a housing is shrink-fitted to a core. FIG. 19B is an explanatory view showing a state after the housing is fitted and contracted.

FIG. 20 is an explanatory view showing a state where a band-shaped member such as a steel band is fastened to the core and the core is assembled.

21 (a) is a plan view showing a state in which a divided end portion and a cutout portion of the outer periphery of a core are fixed by welding, and FIG. 21 (b) is a perspective view thereof.

22 (a) is an explanatory view showing a step of resin-molding the core, and FIG. 22 (b) is a perspective view showing the resin-molded core.

FIGS. 23 (a) to 23 (f) are explanatory views showing various modifications of the element constituting the core back portion. FIG. 23 (g) shows an example in which the element is punched from a band-shaped plate material. Explanatory drawing which shows the state which is pulled out.

FIG. 24 (a) is an explanatory diagram showing a state in which pieces are stacked with one slot pitch shifted for each layer, and FIG.
(B) shows a block in which a plurality of element pieces are stacked, one for each layer.
FIG. 4 is an explanatory diagram showing a state in which the layers are stacked with a slot pitch shifted.

FIG. 25 (a) is a plan view showing an example in which the core back portion and the tooth portion are assembled into a shape in which the tip of the tooth portion is abutted, and FIG. 25 (b) is an assembly of the core back portion and the tooth portion. FIG. 25 is a plan view showing a second embodiment in which the bent shape is a shape in which the tips of the teeth are butted.
FIG. 23C is a plan view illustrating an example in which the core back portion and the tooth portion of FIG.

FIG. 26A is a plan view showing a combined shape of a core back portion and a teeth portion. FIG. 26B is a plan view showing a second form of the coupling shape between the core back portion and the teeth portion. FIG. 26C is a plan view showing a third form of the coupling shape between the core back portion and the teeth portion.

FIG. 27 (a) is an explanatory view illustrating a state in which the teeth are punched out of a belt-shaped material, and FIG. 27 (b) is a perspective view showing the teeth in a stacked state.

FIG. 28 (a) is an explanatory view showing one mode in which the pieces are shifted by one slot pitch, and FIG.
FIG. 28B is a cross-sectional view, FIG. 28C is an explanatory view showing another mode in which the pieces are shifted by one slot pitch, and FIG. 28D is a cross-sectional view thereof.

29 (a) is a plan view showing a state where the base end of the teeth portion is thinned, and FIG. 29 (b) is a cross-sectional view showing a state where the teeth are stacked.

FIG. 30 (a) is a perspective view showing that the teeth are assembled by adjusting the stack thickness by a finishing press before fitting and assembling to the core back part. , FIG.
(B) is a perspective view showing that the core back portion is assembled by adjusting the stack thickness by a finishing press before fitting and assembling the teeth portion.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Coil molding, 1a ... Through-hole, end surface ... 1c, 11 ...
Wire 2 ... core, 21 ... teeth part, 213 ... base end, 21
9, 229: caulking part, 22: core back part, 220 ...
Element piece, 221 teeth connecting portion, 3 stator (stator), 4 housing, 5 shaft, 6 rotor (rotor), 7 steel band, 8 welding portion, 9 mold die, 10 ... resin, 12 ... hole, 15 ... mold, 15a ... bobbin, 15b, 15c, 15d ... pressing mold.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Noriaki Yamamoto 292, Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture Inside of Hitachi, Ltd. (72) Inventor Toshihiko Sakai 7-1-1 Higashi Narashino, Narashino-shi, Chiba Industrial Equipment Division, Hitachi, Ltd. (72) Inventor Suetaro Shibukawa Oita Takaba, Hitachinaka-shi, Ibaraki 2520 Address: In the Automotive Equipment Division of Hitachi, Ltd. 5H615 AA01 BB14 PP01 PP07 PP08 PP10 SS05 SS19

Claims (46)

[Claims] 1. A rotating machine core having a core back portion and a plurality of teeth portions, wherein the teeth portion is formed of a directional silicon steel plate, and the core back portion is formed of a non-directional silicon steel plate. A core for a rotating machine, characterized in that: 2. A rotating machine core having a core back portion and a plurality of teeth portions, wherein the teeth portion and the core back portion are formed of different materials, respectively, and the teeth portion has a higher saturation magnetization than the core back portion. A rotating machine core formed of a large material. 3. The core for a rotating machine according to claim 1, wherein the core back portion has a structure in which a plurality of pieces are continuously arranged in a ring shape and a plurality of layers are stacked. A rotating machine core, characterized in that: 4. A core for a rotating machine having a core back portion and a plurality of teeth portions, wherein the core back portion and the plurality of teeth portions are provided separately, and the core back portion is provided on an inner peripheral side thereof. The tooth part has a plurality of teeth connecting parts connecting the teeth parts, and the base of the teeth part is attached to the teeth connecting part and is connected to the core back part. A core for a rotating machine, characterized by having a structure in which a plurality of element pieces are arranged in a row in a ring and a plurality of layers are stacked. 5. The core for a rotating machine according to claim 4, wherein the core back portion is arranged such that the element pieces are shifted in a circumferential direction in units of a slot pitch between adjacent layers. Core for rotating machine. 6. A rotating machine core having a core back portion and a plurality of teeth portions, wherein the core back portion and the plurality of teeth portions are provided separately, and the core back portion is provided on an inner peripheral side thereof. The tooth part has a plurality of teeth connecting parts connecting the teeth parts, and the base of the teeth part is attached to the teeth connecting part and is connected to the core back part. A core for a rotating machine, having a structure in which blocks formed by stacking a plurality of element pieces are arranged in an annular shape. 7. The rotating machine core according to claim 6, wherein the core back portion has a structure in which the blocks are stacked in a plurality of layers. 8. The rotating machine core according to claim 7, wherein the core back portion disposes the blocks in a circumferential direction in units of a slot pitch between adjacent layers. For core. 9. The rotating machine core according to claim 4, wherein the element has a curved shape. 10. The rotating machine core according to claim 4, further comprising: a tightening member that tightens the core back portion from outside, wherein the tightening member externally moves the core back portion. Wherein each end of each element of the core back portion is brought into circumferential contact with each other. 11. A core for a rotating machine, comprising: a core back portion, a plurality of teeth mounted on an inner peripheral side of the core back portion, and a fastening member for fastening the core back portion from the outside. Has a structure divided at a plurality of locations in the circumferential direction, wherein the fastening member fastens the core back portion from the outside to make the divided portions of the core back portion closely contact in the circumferential direction. A core for a rotating machine. 12. The core for a rotating machine according to claim 11, wherein the core back portion has a connecting portion for connecting the teeth portion on an inner peripheral side, and the connecting portion corresponds to a slot pit. A core for a rotating machine, characterized in that the core is provided for a rotating machine. 13. The rotating machine core according to claim 10, wherein the fastening member is formed of a sleeve, and the core back portion is fitted inside the sleeve. Core for rotating machine. 14. The rotating machine core according to claim 10, wherein the fastening member is a band-shaped member wound around the outer periphery of the core back portion. Core for rotating machine. 15. The rotating machine core according to claim 10, wherein the fastening member is a mold resin surrounding the outer periphery of the core back portion. core. 16. The rotating machine core according to claim 4, wherein the core back portion is formed by welding a series of pieces. 17. A rotating machine core having a core back portion and a plurality of teeth portions, wherein the core back portion and the plurality of teeth portions are provided separately, and the core back portion is provided on an inner peripheral side thereof. The teeth portion has a plurality of teeth connecting portions for connecting the teeth portion, the teeth portion is attached to the core back portion and the base end thereof is attached to the teeth connecting portion, and the tip of each tooth portion, A core for a rotating machine, which is formed in an arc shape and, when mounted on a core back portion, forms a circumference together with the tip of another adjacent tooth portion. 18. A rotating machine core having a core back portion and a plurality of teeth portions, wherein the core back portion and the plurality of teeth portions are provided separately, and the core back portion is provided on an inner peripheral side thereof. The teeth portion has a plurality of teeth connecting portions for connecting the teeth portion, the teeth portion is attached to the core back portion and the base end thereof is attached to the teeth connecting portion, and the tip of each tooth portion, A rotating machine core, which is formed in a linear shape and forms a polygon together with the tips of other adjacent teeth portions in a state of being attached to the core back portion. 19. The rotating machine core according to claim 1, wherein the teeth portion is an integral teeth assembly connected at a tip end side thereof. 20. The rotating machine core according to claim 1, wherein the teeth are formed by laminating independent plate members. 21. The method of claim 4, 5, 6, 7, 8, 9, 1.
The rotating machine core according to any one of 0, 12, 17, 18, 19, and 20, wherein the teeth connecting portion of the core back portion has a dovetailed groove structure, and is provided at a base end of the teeth portion. A core for a rotating machine having a dovetail that fits into the dovetail groove as a connecting part. 22. The method of claim 4, 5, 6, 7, 8, 9, 1.
21. The rotating machine core according to any one of 0, 12, 17, 18, 19, and 20, wherein the thickness of one of the teeth connecting portion of the core back portion and the base end portion of the teeth portion is other than that. A rotating machine core characterized by being thinner than the part. 23. A core back used for a rotating machine core, wherein the core back has a structure in which a plurality of pieces are continuously arranged in an annular shape and a plurality of pieces are laminated. 24. The core back according to claim 23, wherein the element has a tooth connecting portion for connecting a tooth portion to an inner peripheral side of the core back portion, and the tooth connecting portion. The core back is characterized in that the plurality of layers are laminated while maintaining a positional relationship of being aligned in a line in parallel with the central axis of the core. 25. The core back according to claim 23, wherein the element has a portion which is easily deformed when stress is applied as compared with other portions. 26. The core back according to claim 25, wherein a thin portion having a reduced thickness is provided around the bending center as the easily deformable portion. 27. The core back according to claim 26, wherein the thin portions are arranged at different positions between the stacked pieces. 28. The core back according to claim 25, wherein a notch is provided at a bending central portion as the easily deformable portion. 29. The core back according to claim 28, wherein the cutouts are arranged at different positions between the stacked pieces. 30. The core back according to claim 28, wherein the notch is provided in two or more places. 31. The core back according to claim 23, wherein the element has a plurality of caulking portions for fixing the laminated pieces to one another, and one of the caulking portions is a convex portion. And the other is a through hole, wherein the convex portion is press-fitted into a through hole of another laminated piece, and the through hole is a press-fitted convex portion of another laminated piece. A core back, wherein the convex portion and the through-hole are arranged in a positional relationship with the through-hole of the upper and lower element pieces to be laminated and the convex portion. 32. A piece for forming a core back constituting a core for a rotating machine by laminating a plurality of layers, wherein the piece has a curved form in which a plurality of sheets are connected to form a ring. A core back piece having a connecting portion on a peripheral side for connecting teeth of a rotating machine. 33. The core back piece according to claim 32, wherein the connecting portions are provided at least at both ends, and the teeth can be connected when connected to other pieces. A piece for core back, characterized by being formed in a. 34. The core back piece according to claim 32, wherein the connecting portion is provided at at least one position in an intermediate portion. 35. The core back piece according to any one of claims 32, 33, and 34, wherein the connecting portion is provided at at least one position in an intermediate portion and at both ends, and is provided at the both ends. The connecting portion to be connected is formed in such a form that the teeth can be connected when the connecting portions are connected to each other. 36. A method of manufacturing a core for a rotating machine having a core back portion and a tooth portion, wherein a member constituting a core back portion having a tooth connecting portion to which the tooth portion is to be connected is punched out of a belt-shaped member and manufactured. Cut to a length according to the size of the core to be cut, while laminating the members constituting the core back portion to the desired thickness, and bending the teeth connecting portion to the inner peripheral side, both ends of the member And forming a core back portion, having a connection portion with a tooth connection portion of a member constituting the core back portion, and punching out a member in a state where the tips of the respective tooth portions are connected from the belt-shaped member, and manufacturing Cut to a length corresponding to the size of the core to be cut, and laminating a plurality of members constituting the teeth portion to a desired thickness, simultaneously or sequentially (in any order). The tip of the tooth part is bent outward in a ring shape, and both ends of the member are fixed to form a tooth assembly, and a preformed coil molded body is attached to each tooth part of the tooth assembly. The tooth assembly is inserted into the inner periphery of the core back portion, and the connecting portion of the tooth member is attached to the tooth connecting portion, and each tooth portion is fixed to the core back portion. Manufacturing method of machine core. 37. The method of manufacturing a core for a rotating machine according to claim 36, wherein, at the time of forming the core back portion, a piece having a length of at least two slots is punched from a plate material, and each piece is formed of a core back. A method of manufacturing a core for a rotating machine, comprising: sequentially arranging in a circumferential direction, annularly disposing, and laminating every other layer by shifting a plurality of slot pitches including one slot pitch. 38. The method of manufacturing a core for a rotating machine according to claim 36, wherein, when forming the core back portion, a piece having a length of at least two slots is punched from a plate material, and a plurality of each piece is formed. Manufacturing a core for a rotating machine, wherein the laminated blocks are sequentially arranged in a ring shape in a circumferential direction of the core back, and the blocks are laminated while being shifted by a plurality of slot pitches including one slot pitch every other layer of the block. Method. 39. A method for manufacturing a rotating machine core having a core back portion and a tooth portion, wherein the core back portion is formed into a structure divided at a plurality of locations in a circumferential direction, and the teeth portion is connected. A housing having an inner diameter smaller than the outer diameter of the core is expanded by giving a temperature difference, and the core back portion is fitted in the housing, and the housing cools and contracts, thereby forming a circumference of the core. A method for manufacturing a core for a rotating machine, wherein a stress is applied in a direction. 40. A method of manufacturing a rotating machine core having a core back portion and a tooth portion, wherein the core back portion is formed into a structure divided at a plurality of circumferential locations and connected to the tooth portion, A method for manufacturing a core for a rotating machine, wherein a core back portion is tightened from outside by a tightening member so that stress is applied in a circumferential direction of the core. 41. The method for manufacturing a core for a rotating machine according to claim 40, wherein the band-like member tightened by welding is fastened while maintaining the tightened state. Method. 42. The method for manufacturing a core for a rotating machine according to claim 39, wherein a stress is applied in a circumferential direction of the core.
A method for manufacturing a core for a rotating machine, characterized in that a joint portion of an outer peripheral portion of a core is fastened by welding or the like, and a stress remains on an inner circumferential side after the fastening. 43. A method of manufacturing a core for a rotating machine having a core back portion and a tooth portion, wherein the stator is assembled with a resin after assembling the stator coil to apply a stress for reducing a gap between the divided core back portions. A method for manufacturing a core for a rotating machine, characterized in that a resin is poured into a coil end portion and a space in a slot while a tightening pressure is applied by a mold to form a resin. 44. A method for manufacturing a core for a rotating machine having a core back portion and a tooth portion, wherein the tooth portion and the core back portion are formed by laminating plate members, respectively, and a portion where both are connected to each other is originally formed. A method of manufacturing a core for a rotating machine, comprising: forming a tooth portion to be thinner than a thickness of a plate material, and then bonding the teeth portion to the core back portion. 45. A method of manufacturing a core for a rotating machine having a core back portion and a tooth portion, wherein the tooth portion and the core back portion are formed by laminating plate members, respectively, and the laminated tooth portion and the core back portion are formed. A method for manufacturing a core for a rotating machine, wherein each of the cores is compression-molded, and the respective stacking thicknesses are made uniform before joining. 46. A rotating machine having a stator formed by winding a preformed coil around a teeth portion of the rotating machine core according to claim 1.