JP2003061319A - Method for producing stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a stator in which productivity can be enhanced by facilitating the assembling work. SOLUTION: The method for producing a stator comprises a step for forming a laminate 15 by punching a planar magnetic member 11 comprising a plurality of yoke parts 12 linked through a bendable part 12a, a pole tees part 13 formed to project from the central part of each yoke part 12 in the linking direction, and a connecting part 14 formed to connect the forward ends of respective pole tees parts 13 in a sequential feed press die, laminating a specified number of planar magnetic members 11 sequentially and then integrating them by caulking, and a step for forming a magnetic pole part where the gap between the forward ends of respective pole tees parts 13 is skewed by removing each connecting part 14 of the laminate 15 on the outside of the sequential feed press die with a specified width at a specified angle from one end side to the other end side in the laminating direction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotary electric machine such as an electric motor, which is formed by laminating plate-shaped magnetic members and in which the gap between the magnetic pole portions formed at the tips of the magnetic pole teeth portions is skewed in the laminating direction. The present invention relates to a method for manufacturing a stator.

[0002]

2. Description of the Related Art Generally, in a rotating electric machine such as an electric motor, one of a stator and a rotor is skewed in order to prevent torque ripple at the time of starting or cogging during operation. However, in the case of the stator, the coil member must be wound around the magnetic pole teeth portion, but since the winding work is difficult due to the skew, for example, in Japanese Patent Laid-Open No. 1-270757, 14 and 1
As shown in FIG. 5, a protrusion 1b having a dovetail-shaped cross section is formed at the base of the magnetic pole teeth 1 having a skewed magnetic pole portion 1a, and the protrusion 1b is formed on the inner peripheral surface of the annular yoke 2. After forming the recessed portion 2a which can be fitted and winding the coil member 3 around each magnetic pole teeth 1,
The protrusion 1b is fitted into the recess 2a so that the magnetic pole teeth 1
It is disclosed that the winding work of the coil member 3 is facilitated by forming the stator integrally with the yoke 2.

[0003]

The conventional stator is constructed as described above, the magnetic pole teeth 1 can be separated from the yoke 2, and the coil members 3 are wound around the respective magnetic pole teeth 1 and then integrated. Although the winding work of the coil member 3 is facilitated by the above, the work of winding the coil member 3 around each magnetic pole tooth 1 and the protrusion 1b of each magnetic pole tooth 1 around which the coil member 3 is wound. Are required to be fitted into the recesses 2a of the yoke 2 one by one and integrated, and the work of connecting the coil members 3 of the respective magnetic pole teeth 1 and the like is required, so that the assembly is troublesome and the productivity is reduced. There was a problem.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a method of manufacturing a stator which can facilitate the assembling work and improve the productivity. It is a thing.

[0005]

According to a first aspect of the present invention, there is provided a stator manufacturing method, comprising: a plurality of yoke portions connected via bendable portions; and a central portion of each yoke portion in a connecting direction. A magnetic pole teeth portion formed to project,
A plate-shaped magnetic member consisting of a connecting portion formed so as to connect the tips of the magnetic pole teeth portions is punched in a progressive feed press die, a predetermined number of sheets are sequentially stacked, and integrated by laminating and stacking. The step of forming the body and removing the connecting portions of the laminated body with a predetermined width from one end side to the other end in the laminating direction at a predetermined angle outside the progressive press die, thereby leading ends of the magnetic pole teeth portions. And the step of forming a magnetic pole part in which the gap between the two is skewed.

The stator manufacturing method according to a second aspect of the present invention is the method of manufacturing the stator according to the first aspect, wherein the plurality of divided laminated bodies on which the plate-shaped magnetic members are stacked are alternately turned upside down and stacked. By doing so, a laminated body is formed.

Further, a stator manufacturing method according to a third aspect of the present invention is the method of manufacturing the stator according to the first or second aspect, after forming the bobbin member around which the coil member is wound by resin integral molding in the molding die. The part is removed.

According to a fourth aspect of the present invention, in the stator manufacturing method according to any one of the first to third aspects, the skew angle at the end portion in the stacking direction and the skew angle at the central portion are formed differently. It was done like this.

According to a fifth aspect of the present invention, in the stator manufacturing method according to any one of the first to third aspects, the skew is formed in a zigzag shape.

According to a sixth aspect of the present invention, there is provided a stator manufacturing method according to any one of the first to fifth aspects, wherein the connecting portion is removed by a laser.

According to a seventh aspect of the present invention, in the stator manufacturing method according to any one of the first to fifth aspects, the removing process of the connecting portion is performed on the surface of the connecting portion opposite to the yoke portion. This is performed by a die arranged in contact with each other and a punch arranged between the yoke portion and the connecting portion.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. Embodiment 1. 1 is a front view showing a structure of a stator according to Embodiment 1 of the present invention, FIG. 2 shows a first step of a manufacturing method of the stator in FIG. 1, (A) is a plan view,
(B) is a perspective view, FIG. 3 shows a second step of the method for manufacturing the stator in FIG. 1, (A) is a plan view, (B) is a perspective view, and FIG. 4 is a second step shown in FIG. 1A shows a state in which magnetic pole portions are formed, FIG. 5A is a plan view, FIG. 5B is a perspective view, FIG. 5 is a plan view showing a third step of the stator manufacturing method in FIG. 1, and FIG. FIG. 14 is a plan view showing a fourth step of the stator manufacturing method in FIG.

In the figure, 11 is a bendable portion 12a.
A plurality of yoke portions 12 connected to each other via magnetic poles, a magnetic pole teeth portion 13 formed so as to project from a central portion of each yoke portion 12 in the connecting direction, and a magnetic pole teeth portion 13
A plate-shaped magnetic member 15 formed by punching in a progressive press die, and a connecting portion 14 formed so as to connect the tip ends of the plate-shaped magnetic members 11. It is a laminated body integrally formed by punching and caulking.

Reference numeral 16 is a magnetic pole portion formed at the tip of the magnetic pole teeth portion 13 by removing a part of the connecting portion 14, and 17 is an inner surface of the yoke portion 12, side surfaces of the magnetic pole teeth 13 and the magnetic pole portion 16. The bobbin member is formed along the inner surface and is formed by resin integral molding. Reference numeral 18 is a winding machine that winds the supplied electromagnetic wire 19 around the bobbin member 17 to form a coil member 20, and 21 is a coil member 20.
The stator 15 is formed in an annular shape by bending the laminated body 15 in which is formed so that each magnetic pole teeth portion 13 is located inside via the portion 12a.

Next, a method of manufacturing the stator according to the first embodiment configured as described above will be described with reference to the drawings. First, as shown in FIG. 2, a plurality of yoke portions 12 connected via bendable portions 12a, and magnetic pole teeth portions 13 formed so as to respectively project from central portions of the respective yoke portions 12 in the connecting direction. A plate-shaped magnetic member 11 including a connecting portion 14 formed so as to connect the tips of the magnetic pole teeth portions 13 is punched in a progressive press die to stack a predetermined number of sheets, and integrated by punching and caulking. Then, the laminated body 15 is formed.

Next, as shown in FIG. 3, the hatched portion of the connecting portion 14 is subjected to removal processing by, for example, a laser, and at the tip of each magnetic pole tooth portion 13 as shown in FIG. The magnetic pole portions 16 in which the gaps (indicated by g in the figure) are skewed are formed. Next, as shown in FIG. 5, the bobbin member 17 is formed by resin integral molding along the inner surface of the yoke portion 12, the side surface of the magnetic pole teeth portion 13 and the inner surface of the magnetic pole portion 16. Next, as shown in FIG. 6, an electromagnetic wire 19 is wound around each magnetic pole teeth portion 13 via a bobbin member 17 by a winding machine 18 to form a coil member 20.
To form. Then, finally, the laminated body 15 is attached to the portion 12a.
The stator 21 is completed by bending each of the magnetic pole teeth portions 13 through the to form an annular shape and fixing the positions shown by (A) in FIG. 1 by welding, for example.

As described above, according to the first embodiment, the plate-shaped magnetic member 11 including the yoke portion 12, the magnetic pole teeth portion 13 and the connecting portion 14 is punched in a progressive press die and a predetermined number of sheets are sequentially printed. The stacked body 15 is formed by stacking and punching and unifying, and each connecting portion 14 of the stack 15 is formed outside the progressive press die with a predetermined width and at a predetermined angle from one end side to the other end side in the stacking direction. By removing processing with
The magnetic pole portions 16 having skewed gaps are formed at the tips of the magnetic pole teeth portions 13,
After the coil member 20 is wound around each of them, the laminated body 15 is bent so that the magnetic pole teeth portions 13 are inward so as to form an annular shape, so that the stator 21 is configured. Therefore, the assembling work is easy. To improve productivity, and by performing removal processing with a laser,
The force applied to the work piece during processing can be slightly suppressed, and chips are not scattered, so that the quality can be improved.

Embodiment 2. FIG. 7 shows the structure of a divided laminate of stators according to Embodiment 2 of the present invention.
8A is a plan view, FIG. 8B is a front view, and FIG. 8 is a front view showing a configuration of a laminated body formed by stacking the divided laminated bodies in FIG. 7. In the figure, the same parts as those in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

Reference numeral 22 denotes a plurality of divided laminated bodies formed by punching the plate-shaped magnetic members 11 in a progressive press die, sequentially stacking the sheets in a number corresponding to the number of divisions, and fixing and integrating them by punching and caulking. 23, the plurality of divided laminated bodies 22 are alternately turned over as shown in FIG. 8 and stacked so that their one end sides 22a and 22b are sequentially different sides in the laminating direction, and they are fixed to each other by, for example, welding. This is a laminated body integrally formed.

In the stator manufacturing method according to the second embodiment of the present invention, first, as shown in FIG.
1 are punched in a progressive press die, stacked one by one in accordance with the number of divisions, and punched to be fixedly integrated to form a plurality of divided laminated bodies 22. Next, each of the divided laminated bodies 22 is alternately turned over as shown in FIG. 8 and stacked so that the one end side 22a and the other end side 22b are sequentially different sides in the laminating direction, and they are welded to each other. By being fixed, they are integrated to form a laminated body 23.

Although not shown, as in the first embodiment, a predetermined portion of the connecting portion is removed by laser processing, for example, to skew the gap between the magnetic pole teeth portions at the tips thereof. Forming a magnetic pole part formed on each magnetic pole part, winding a coil member around each magnetic pole taste part through a bobbin member, and then bending the laminated body 23 so that each magnetic pole taste part is on the inside to form an annular shape. This completes the stator.

As described above, according to the second embodiment, the plurality of divided laminated bodies 22 are formed by stacking the plate-shaped magnetic members 11 by the number corresponding to the number of divisions, and the divided laminated bodies 22 are alternately arranged. Turn it over to the other end 22a and the other end 22b.
Are stacked so as to sequentially become different sides in the stacking direction, and the stacked body 23 is formed by fixing and unifying each other. Therefore, when stacking the plate-shaped magnetic members 11, one end side 22a and Since variations in the thickness in the stacking direction that occur on the other end side 22b can be offset by each other,
It is possible to make the variation in the thickness of the laminated body 23 uniform and improve the quality.

Embodiment 3. FIG. 9 is a plan view showing an essential part of a manufacturing process of a stator according to the third embodiment of the present invention. In the figure, the same parts as those in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted. 24 is shown in FIG.
As shown in (A), each connecting portion 14 has a magnetic pole teeth portion 13.
Is a bobbin member formed by resin integral molding along the inner surface of the yoke portion 12, the side surface of the magnetic pole teeth portion 13 and the inner surface of the coupling portion 14 in the molding die in a state of being connected between the tips.

As described above, according to the third embodiment, the bobbin member 24 is formed by resin integral molding in the molding die in a state where the coupling portions 14 are coupled between the tips of the magnetic pole teeth portions 13. Then, as in the first embodiment, a predetermined portion of the connecting portion 14 is removed, and then the magnetic pole portion 16 in which the gap between the two is skewed is formed.
Therefore, the bobbin member 24 can be formed while the shape of the laminated body 15 is firm due to the connecting portion 14.
Therefore, the resin-integrated molding work is facilitated and the productivity can be further improved.

Fourth Embodiment FIG. 10 is a front view showing the configuration of the main part of the stator according to the fourth embodiment of the present invention. In the configuration of each of the above-described embodiments, the case where the gap g between the adjacent magnetic pole portions 16 is linearly skewed in the stacking direction has been described, but the present invention is not limited to this, and the end portion in the stacking direction is not limited to this. The skew angle and the skew angle of the central portion may be formed to be different from each other.

That is, even if a predetermined skew angle cannot be obtained due to dimensional constraints, the magnetic flux density at the end portion in the stacking direction is smaller than that at the central portion, so the skew angle at the central portion can be reduced. A skew effect can be sufficiently obtained by making it larger than the skew angle of the end portion. Further, in a linear skew, when the magnetic saturation on the tip side of the magnetic pole portion 16 becomes remarkable due to the influence of the leakage magnetic flux generated in the axial direction, in order to suppress the high frequency due to this magnetic saturation, FIG. As shown in A), by making the skew angle at the central portion smaller than the skew angle at the end portion, magnetic saturation can be relaxed and a sufficient skew effect can be obtained. Furthermore, by forming the skew in a zigzag shape as shown in FIG.
The thrust force generated in the axial direction can be reduced, and the vibration and noise generated by this thrust force can be reduced.

Embodiment 5. FIG. 11 is a diagram showing one step of a stator manufacturing method according to Embodiment 5 of the present invention,
12 is a diagram showing the next step of the step in FIG. 11, FIG.
FIG. 13 is a diagram showing a step subsequent to the step in FIG. 12. In the figure, the same parts as those in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted. Reference numeral 25 is a die disposed in contact with the surface 14a of the connecting portion 14 opposite to the yoke portion 12, and 26 is a punch disposed in each space 27 between the yoke portion 12 and the connecting portion 14. is there.

In the stator manufacturing method according to the fifth embodiment, first, as shown in FIG. 11, the die 25 is moved in a direction indicated by an arrow A in FIG.
The punch 26 is placed in contact with the surface 14a on the side opposite to 2, and the punches 26 are arranged in the spaces 27 between the yoke portion 12 and the connecting portion 14, respectively. Next, as shown in FIG. 12, punch 2
6 is moved in the direction shown by the arrow B in the figure to be fitted with the die 25, thereby punching out a part of the connecting portion 14 to separate the fragment 14b. Then, as shown in FIG. 13, the fragment 14b is separated from the connecting portion 14, so that the magnetic pole portions 16 having the gap g skewed between each other are formed at the tips of the magnetic pole teeth portions 13.

As described above, according to the fifth embodiment, the die 25 is placed in contact with the surface 14a of the connecting portion 14 opposite to the yoke portion 12, and the space between the yoke portion 12 and the connecting portion 14 is provided. Since the punches 26 are arranged in the respective spaces 27 and the fragments 14b are separated from the connecting portion 14 by punching the die 25 and the punch 26, the magnetic pole portions 16 are formed, so that the machining can be easily performed in a short time. Further, productivity can be improved.

Although not described in the above-mentioned respective embodiments, for example, in FIG. 2A, the connecting portion 14 is provided from the tip of the magnetic pole teeth portion 13 located at both ends to the outside.
Although a part of each of the two is protruding, it goes without saying that the end faces of the other parts are also formed so as to have a skewed gap between them when the stacked body 15 is formed in an annular shape.

[0031]

As described above, according to the first aspect of the present invention, the plurality of yoke portions connected via the bendable portion and the respective yoke portions protruding from the central portion in the connecting direction are formed. The magnetic pole teeth portion and a connecting portion formed so as to connect the tips of the magnetic pole teeth portions with each other, the plate-shaped magnetic member is punched in a progressive press die and a predetermined number of sheets are sequentially stacked, By the process of integrally forming a laminated body by punching and caulking, and by removing each connecting portion of the laminated body with a predetermined width outside the progressive press die at a predetermined angle from one end side to the other end in the stacking direction. Since the method includes the step of forming the magnetic pole portions in which the gaps between them are skewed at the tips of the magnetic pole teeth portions, a method of manufacturing a stator that facilitates assembly work and improves productivity is provided. Can .

According to a second aspect of the present invention, in the first aspect, the plurality of divided laminated bodies in which the plate-shaped magnetic members are stacked are alternately turned upside down to be stacked and fixed to each other so that they are laminated. Since the body is formed, it is possible to provide the manufacturing method of the stator capable of improving not only the productivity but also the quality.

According to a third aspect of the present invention, the bobbin member around which the coil member is wound is formed by resin integral molding in the molding die according to the first or second aspect, and then the connecting portion is removed. Therefore, it is possible to provide a stator manufacturing method capable of further improving productivity.

According to a fourth aspect of the present invention, in any one of the first to third aspects, the skew angle at the end in the stacking direction and the skew angle at the center are formed differently. It is possible to provide a stator manufacturing method that can obtain a sufficient skew effect.

According to a fifth aspect of the present invention, in any one of the first to third aspects, the skew is formed in a zigzag shape, so that the production of a stator capable of reducing vibration and noise can be achieved. A method can be provided.

According to a sixth aspect of the present invention, in any one of the first to fifth aspects, the removing process of the connecting portion is performed.
Since the process is performed by the laser, it is possible to provide the stator manufacturing method capable of improving the quality.

According to a seventh aspect of the present invention, in any one of the first to fifth aspects, the removing process of the connecting portion is performed.
Since the die is arranged in contact with the surface of the connecting portion opposite to the yoke portion and the punch is arranged between the yoke portion and the connecting portion, the productivity is further improved. It is possible to provide a method of manufacturing a stator that is capable of manufacturing.

[Brief description of drawings]

FIG. 1 is a front view showing a configuration of a stator according to a first embodiment of the present invention.

2A and 2B show a first step of the method for manufacturing the stator in FIG. 1, in which FIG. 2A is a plan view and FIG. 2B is a perspective view.

3A and 3B show a second step of the method for manufacturing the stator in FIG. 1, in which FIG. 3A is a plan view and FIG. 3B is a perspective view.

4A and 4B show a state in which a magnetic pole portion is formed in the second step shown in FIG. 3, FIG. 4A being a plan view and FIG. 4B being a perspective view.

FIG. 5 is a plan view showing a third step of the method of manufacturing the stator in FIG.

FIG. 6 is a plan view showing a fourth step of the method of manufacturing the stator in FIG.

7A and 7B show a structure of a divided laminated body of a stator according to Embodiment 2 of the present invention, FIG. 7A being a plan view and FIG. 7B being a front view.

8 is a front view showing a configuration of a laminated body formed by stacking the divided laminated bodies in FIG.

FIG. 9 is a plan view showing an essential part of a manufacturing process of a stator according to the third embodiment of the present invention.

FIG. 10 is a front view showing a configuration of a main part of a stator according to a fourth embodiment of the present invention.

FIG. 11 is a diagram showing a step in the method of manufacturing the stator according to the fifth embodiment of the present invention.

12 is a diagram showing a step subsequent to the step in FIG. 11. FIG.

FIG. 13 is a diagram showing a step subsequent to the step in FIG.

FIG. 14 is a front view showing the structure of a conventional stator.

15 is a perspective view showing a configuration of magnetic pole teeth in FIG.

[Explanation of symbols]

11 plate-like magnetic member, 12 yoke part, 12a part,
13 magnetic pole teeth portion, 14 connecting portion, 14a surface, 1
4b fragment, 15,23 laminated body, 16 magnetic pole part, 1
7, 24 bobbin members, 20 coil members, 21 stators, 22 divided laminated bodies, 25 dies, 26 punches.

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Hiroyuki Akita             2-3 2-3 Marunouchi, Chiyoda-ku, Tokyo             Inside Ryo Electric Co., Ltd. (72) Inventor Akira Hashimoto             2-3 2-3 Marunouchi, Chiyoda-ku, Tokyo             Inside Ryo Electric Co., Ltd. F-term (reference) 5H002 AA09 AB01 AC08 AE06 AE07                       AE08                 5H604 AA08 BB01 BB08 BB14 CC01                       CC05 CC16 DA14 DB01 DB26                       PB03 PE06                 5H615 AA01 BB01 BB05 BB14 BB16                       PP01 PP06 PP07 PP08 PP12                       QQ02 QQ19 RR01 SS03 SS05                       SS11 SS13

Claims (7)

[Claims] 1. A plurality of yoke portions connected via bendable portions, magnetic pole teeth portions formed so as to respectively project from a central portion of each yoke portion in a connecting direction, and tips of the magnetic pole teeth portions. A step of forming a laminated body by punching a plate-shaped magnetic member consisting of a connecting portion formed so as to connect between the sheets and sequentially stacking a predetermined number of sheets in a progressive press die, and integrally by punching and caulking, And, outside the progressive press die, the connecting portions of the laminate are removed with a predetermined width and from the one end side to the other end in the stacking direction at a predetermined angle, so that the tip ends of the magnetic pole teeth portions are mutually removed. A method for manufacturing a stator, comprising a step of forming magnetic pole portions in which a gap between them is skewed. 2. A laminated body is formed by alternately turning over a plurality of divided laminated bodies in which plate-shaped magnetic members are laminated and stacking them, and fixing them to each other. A method for manufacturing the described stator. 3. The bobbin member around which the coil member is wound is formed by resin-integral molding in a molding die, and then the connecting portion is removed. Stator manufacturing method. 4. The method for manufacturing a stator according to claim 1, wherein the skew angle at the end in the stacking direction and the skew angle at the center are formed differently. 5. The stator manufacturing method according to claim 1, wherein the skew is formed in a zigzag shape. 6. The method for manufacturing a stator according to claim 1, wherein the removal processing of the connecting portion is performed by a laser. 7. The removing process of the connecting portion is performed by a die arranged in contact with a surface of each connecting portion opposite to the yoke portion, and a punch arranged between the yoke portion and the connecting portion. The method for manufacturing a stator according to any one of claims 1 to 5, which is performed.