JP2003088009A - Method of manufacturing motor with core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a motor core whose lamination calked part is released from machining distortion, residual stress, and a broken part of an insulation film. SOLUTION: A connection part 26 is formed inside a center circle between an inner diameter ϕa2 of a reference hole 23 and an outer diameter ϕc2 of a circular base 21 of a core 20 by circumferentially continuous calking. The connection part 26 is cut off and removed to form a cut-off part 27 and a core holder fixing part is formed on the removed surface of the cut-off part 27. As a broken insulation part and parts containing machining distortion and residual stress are removed together, iron loss caused by the insulation defect is eliminated and causes producing disturbances in a flux distribution, and a rotating alternating magnetic field and flux harmonic components are extinguished. Therefore, the electromagnetic performance of steel plate can be fully utilized, so that a motor efficiency can be improved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated core of an electromagnetic application device, and more specifically, to an outer rotor of a motor, a stator core for an inner rotor,
The present invention relates to an armature core laminating means such as a brushless motor.

[0002]

2. Description of the Related Art FIG. 5 shows the structure of a general motor 100 with a core in a partial cross section. The core 101 that constitutes the magnetic circuit is
The motor 100 shown in FIG. 5 has the optimal number of slots depending on the number of poles of the magnet 102.
Has 4 poles and the number of core slots is 6 poles. The core 101 is a laminated core in which a plurality of thin steel plates 103 are laminated in order to reduce iron loss, and they are connected to each other by a half-blanking caulking 104, a V-shaped caulking, or the like to have an integral structure.

FIG. 6 shows a laminated core 101 used in the motor 100 of FIG. The laminated core 101 is supported by the bearing metal 105 and has a circular base 107 for fixing the rotatable shaft 106.
8 is extended to form a magnetic pole on each core rib 108 by energizing the coil winding 109. As shown in FIG. 6, in the laminated core 101, a laminated crimp portion 104 is provided at each of the core ribs 108 to secure fixing strength and accuracy.

[0004]

In recent years, it has been demanded that all types of motors have high efficiency, and in order to cope with this, improvement of iron loss (overcurrent loss) of the motor core is inevitable. Therefore, it is desirable that the laminated core has a thinner plate thickness, and a structure having a plate thickness of 0.2 mm or less is currently under study. However, when the plate thickness becomes thin, it is not possible to sufficiently secure the lamination strength by the conventional fixing means such as half blanking. In addition, increasing the number of laminated parts improves the strength, but mechanical working strain and residual stress act on the laminated caulking part, the insulating coating of the steel plate is destroyed, the core becomes conductive, and local iron loss occurs. Motor performance is reduced.

Particularly in a multi-pole motor, since many caulking portions are required, iron loss tends to increase and motor characteristics tend to deteriorate. On the other hand, in a motor having a large core laminated plate thickness, in addition to an increase in iron loss, a large amount of stacking error occurs during high-speed rotation, and the required dimensional accuracy cannot be ensured. The applicant is Japanese Patent Publication No. 8-437
No. 1 proposed to crimp a part that does not affect the magnetic circuit, but it is effective only in the case of a core shape with a sufficient space. Even in this case, the effects of machining strain and residual stress are not completely dealt with, and this causes disturbance of the magnetic flux distribution and the rotating alternating magnetic field during the operation of the motor, and the generation of magnetic flux harmonic components.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a motor core structure in which the caulking fixing portion can be separated from the motor core. That is, it is necessary to prevent the crimped portion from remaining in the core, including the conventional crimped content.

[0007]

In order to achieve the above object, a method of manufacturing a motor with a core according to the present invention is a method of manufacturing a motor with a core comprising a laminated core in which a plurality of cores are laminated. Has a plurality of core ribs extending in the radial direction around which the coil winding is wound and a connecting portion having a central hole at the center where the core ribs are integrated, and a portion closer to the center than the magnetic path forming portion of the connecting portion. The laminated core was integrated by the crimped crimp portion, and then the crimp portion was removed.

The caulking portion is formed discontinuously in the circumferential direction inside the center between the outer diameter of the connecting portion and the inner diameter of the central hole. Further, the crimped portion is formed on a line extending in the radial direction passing near the center of the circumferential width of the core rib. Further, the crimped portion is formed continuously in the circumferential direction inside the center of the outer diameter of the connecting portion and the inner diameter of the central hole, and the core holder fixing portion is formed on the removal surface from which the crimped portion is removed. Further, the "after" is after the coil winding, after applying the insulating paint to the core, or after mounting the insulator.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a method of manufacturing a motor with a core according to the present invention will be described below with reference to the drawings. FIG. 1 shows a first embodiment of a brush motor with a 6-pole core. (A) is a top view, (b) is sectional drawing which followed the bb line | wire of (a). In the figure, the core element 10 has six core ribs 12 extending radially from the connecting portion 11 to form a magnetic pole. Inner diameter φa1 at the center of core element 10
The reference hole 13 as the central hole of the is penetrated. A plurality of core elements 10 (five in FIG. 1) having the same shape and having an insulating coating are laminated to match the outer shape with the reference hole 13 as a boundary.

The motor core 14 constituted by the laminated body of the core elements 10 has magnetic poles at equal intervals inside the center between the inner diameter φa1 of the reference hole 13 and the outer diameter φc1 of the connecting portion 11 along the circumference 15 of the diameter φb1. The crimping portions 16 are formed one by one on a line extending in the radial direction passing near the center of the circumferential width of the core rib 12 to be formed. The caulking portion 16 is further subjected to an insulating coating treatment, and after the coil winding 19 is wound, the caulking portion 16 is withdrawn including the peripheral edge where the processing strain remains, thereby configuring the motor core 14 (see FIG. 1C).

With this configuration, the pull-out portion 17 has a small effect on the cross-sectional area of the magnetic path, and finally the core portion forming the magnetic circuit has iron loss and working strain due to dielectric breakdown due to caulking. It is possible to eliminate the structure that affects the motor characteristics due to residual stress and residual stress. The reference hole 13 serves as a central shaft fixing hole (not shown), and the motor core 14 serves as an inner rotor core.

FIG. 2 shows a second embodiment of another motor core. (A) is a top view, (b) is sectional drawing which followed the bb line | wire of (a). Similar to the first embodiment, the core element 20 has six core ribs 22 extending radially from the connecting portion 21 to form magnetic poles. A reference hole 23 having an inner diameter .phi.a2 penetrates through the center of the core element 20. A plurality of core elements 20 (five in FIG. 2) having the same shape and having an insulating coating are laminated to match the outer shape with the reference hole 23 as a boundary.

The motor core 24 constituted by the laminated body of the core elements 20 has an inner diameter φa 2 of the reference hole 23 and a connecting portion 21.
The caulking portion 26 is caulked into a circular shape having a diameter φb2 inside from the center of the outer diameter φc2. The caulking portion 26 is further subjected to an insulation coating treatment, and after winding the coil winding 29,
The motor core 24 is removed including the peripheral edge where the processing strain remains (see FIG. 2C).

With this structure, the influence of 27 on the cross-sectional area of the magnetic path is slight, and in the core portion that finally forms the magnetic circuit, iron loss, processing strain and residual stress due to dielectric breakdown due to caulking are performed. The configuration that affects the motor characteristics due to can be eliminated. The fixing portion of the core holder (not shown) is formed in the pulling-out portion 27 which is removed by pulling out the caulking portion, and the motor core 24 serves as a stator core.

FIG. 3 shows an embodiment of a method of manufacturing a cored motor according to the present invention according to a third embodiment of a 12-pole core. Also in this core element 30 having a multi-pole structure, twelve core ribs 32 are radially extended from the connecting portion 31 to form magnetic poles, as in the above embodiment. A reference hole 33 having an inner diameter .phi.a3 penetrates through the center of the core element 30. A caulking portion 36 is formed in a circular shape having a diameter φb3 inside the center between the inner diameter φa3 of the reference hole 33 and the outer diameter φc3 of the connecting portion 31. Reference hole 3
3, a fan-shaped hole 35 is intermittently provided at a position corresponding to every other core rib 32 along the diameter φb3 of the crimp portion 36 on the outer periphery of No. 3, so as to have a dead zone against stress and strain due to crimping and influence on the magnetic path. Alleviate.

A plurality of core elements 30 (10 in FIG. 3) having the same shape and having an insulating coating are laminated to match the outer shape with the reference hole 33 as a boundary. Core element 30
The motor core 34 constituted by the laminated body also has a semi-blanked caulking portion 38 also on the outer peripheral portion 37 of each pole in order to secure the fixing strength per pole. Figure 4 (a)
As shown in the plan view and (b) in the sectional view taken along the line bb of (a), the crimped crimped portions 36 and 38 are subjected to insulation coating treatment, and after the coil winding 39 is wound, The motor core 34 is removed including the peripheral edge where the processing distortion remains.
Make up. The motor core 34 serves as a stator core.

Although the embodiments have been described above, the present invention is not limited to the illustrated embodiments, and various changes in details regarding the shape, configuration, etc. can be made without departing from the constituent features of the invention. It is expected that modifications such as reconfiguration of parts and parts can be made. That is, in the case of the inner rotor structure, the rotor structure in the reluctance motor or the embedded magnet motor may have a laminated structure of thin plates. In this case, as an application example of the above configuration, it is conceivable to simultaneously configure and utilize the rotor structure at the inner peripheral portion that has been cut off via the connecting portion.

[0018]

As is apparent from the above description, claim 1
According to the method for manufacturing a motor with a core according to the present invention described in (4) and (5), in the method for manufacturing a motor with a core including a laminated core in which a plurality of cores are laminated, the core has a radial direction in which a coil winding is wound. Has a plurality of core ribs extended to the core rib and a connecting portion having a central hole at the center where the core ribs are integrated, and the laminated core is integrated by a caulking portion crimping the central side from the magnetic path forming portion of the connecting portion. Since the caulking portion is removed after that, the caulking portion for fixing the core is not processed in the core-shaped magnetic path, so that the cross-sectional area of the core forming the magnetic path is not reduced. Moreover, since the crimping position for avoiding the magnetic path is not separately provided outside the range of the core shape, the change of the press molding die is slight. In particular, precision is ensured by caulking the center side of the magnetic path forming part of the connecting part, and it functions as a reference hole when the rotary shaft is press-fitted into the center hole or when the rotor is installed in the center hole. be able to.

Further, since the dielectric breakdown portion due to the caulking and the portion including the processing strain and the residual stress are removed together, the iron loss due to the insulation failure is not generated, and the magnetic flux distribution during the motor operation and the disturbance of the rotating alternating magnetic field and the magnetic flux The cause of the generation of harmonic components disappears. Therefore, the electromagnetic performance of the steel sheet can be fully utilized and the motor efficiency can be improved.

According to the method of manufacturing a cored motor according to the second aspect of the present invention, the caulking portion is circumferentially inward from the center between the outer diameter of the connecting portion and the inner diameter of the central hole. Since it was formed continuously, using the central shaft fixing hole as a reference,
By forming the connecting portion at the close position, it is possible to improve the dimensional accuracy in the integral laminated shape, which is difficult to obtain the laminated accuracy at the conventional laminated crimping position. In addition, the dimensional accuracy can be improved to close the air gap and improve the motor characteristics.

According to the method of manufacturing a cored motor according to the third aspect of the present invention, since the caulking portion is formed on a line extending in the radial direction passing near the center of the circumferential width of the core rib portion, A core structure with sufficient fixing strength can be formed even if the steel plate used for the core is made thin to improve the efficiency of the motor.

According to the method for manufacturing a motor with a core of the present invention as defined in claim 4, the crimped portion is circumferentially continuous inside the center between the outer diameter of the connecting portion and the inner diameter of the central hole. The core holder fixing portion for fixing the core holder is formed by the removal surface obtained by removing the crimped portion, so that the iron loss as described above is improved,
In particular, the larger the number of core poles and the thicker the core lamination thickness, the greater the effect of improving the multipolar cores and thick cores, which were disadvantageous.

[Brief description of drawings]

FIG. 1 is a component diagram illustrating a first embodiment of a core in a method of manufacturing a motor with a core according to the present invention, in which (a) is a plan view showing an array of crimping positions, and (b) is (b) of (a). -B is a cross-sectional view taken along the line b, and (c) is a cross-sectional view with the caulked portion removed.

2A and 2B are component diagrams illustrating a second embodiment of a core in the method of manufacturing a motor with a core according to the present invention, in which FIG. 2A is a plan view showing an arrangement of crimping positions, and FIG. -B is a cross-sectional view taken along the line b, and (c) is a cross-sectional view with the caulked portion removed.

3A and 3B are component diagrams illustrating a third embodiment of a core in the method of manufacturing a motor with a core according to the present invention, in which FIG. 3A is a plan view showing an array of crimping positions, and FIG. It is sectional drawing along the -b line.

4A is a plan view of the core of FIG. 4 with a crimped portion removed, and FIG. 4B is a sectional view taken along line bb of FIG.

FIG. 5 is a side view showing an example of a general motor in a partial cross section.

6A and 6B are component views of a core used in the motor of FIG. 5, FIG. 6A is a plan view, and FIG. 6B is a sectional view taken along line bb of FIG.

[Explanation of symbols]

10 core elements 11 Connection 12 core ribs 13 Reference hole 14 Motor core 15 circle 16 Caulking part 17 Cut-off part 19 coil winding

Claims (5)

[Claims] 1. A method for manufacturing a motor with a core, which comprises a laminated core in which a plurality of cores are laminated, wherein the core has a plurality of core ribs extending in a radial direction around which a winding is wound, and a center in which the core ribs are integrated. A core characterized in that it has a connecting portion with a central hole, and the laminated core is integrated by a caulking portion in which the central side of the magnetic path forming portion of the connecting portion is crimped, and then the caulking portion is removed. Of manufacturing a built-in motor. 2. The cored motor according to claim 1, wherein the caulking portion is formed in a circumferentially discontinuous manner inside a center between an outer diameter of the connecting portion and an inner diameter of the central hole. Manufacturing method. 3. The method of manufacturing a motor with a core according to claim 2, wherein the caulking portion is formed on a line extending in a radial direction passing through a vicinity of a center of a circumferential width of the core rib. 4. The caulking portion is formed continuously in the circumferential direction inside the center between the outer diameter of the connecting portion and the inner diameter of the center hole, and the core holder fixing portion is formed on the removal surface from which the caulking portion is removed. The method of manufacturing a motor with a core according to claim 1, wherein the motor has a core. 5. The “after” means that the coil winding is performed, the insulating coating is applied to the core, or the insulator is attached.
A method of manufacturing a motor with a core according to 1.