JP2003143781A - Stator core of rotary machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator core wherein the yield of the material thereof is high when a stator core plate is stamped out from a steel plate and the retaining structure of laminated stator core plate is simple. SOLUTION: A steel plate wherein tooth portions and connecting portions are strung out long is spirally wound to form laminated tooth portions 2. Magnetic powder is compression-molded around the tooth portions 2, and the laminated tooth portions 2 are fixed in a thus obtained compression molded cylinder 3. Thus, a stator core 1 can be simply manufactured with the high yield of the material. The stator core is excellent in recyclability, and the materials can be easily separated when the stator 1 is disposed of.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a stator core of a rotating machine. In particular, the present invention relates to a stator core that can be effectively used for manufacturing a stator core, and can be easily separated by material when a stator manufactured by winding a coil around the stator core is discarded. The invention also relates to a method of manufacturing the stator core.

[0002]

2. Description of the Related Art A stator core used in a rotating machine such as an electric motor or a generator generally has a stator core outer peripheral portion serving as an outer ring yoke, and a tooth portion having a plurality of tooth portions protruding inward. This stator core is usually
It is manufactured by punching a substantially ring-shaped stator core plate having tooth portions protruding inward from a steel plate such as an electromagnetic steel plate, and laminating a large number of punched stator core plates. The stator is manufactured by winding a coil around the teeth portion of the stator core.

An example of material removal when the above stator core plate is pressed out is shown in FIG. 13 and subsequent figures. FIG.
Is one steel plate P to one stator core plate S1
In the case of punching, the parts other than the stator core outer peripheral part B and the teeth part T having a large number of tooth parts projecting inward thereof are wasted, and much material is wasted. FIG. 14 shows a case where one stator core plate S1 and one rotor core plate R1 are punched out from one steel plate P at the same time or in sequence. Compared with FIG. 13, waste of materials is reduced, but There is a lot of waste. FIG. 15 shows a case in which one stator core plate is divided into sectors and the divided sectors S2 are punched out, and the waste of material is small. However, when punching is divided into sectors S2 as shown in FIG. 15, as shown in FIG. 16, it is necessary to arrange a large number of sectors S2 on the circumference and stack them while combining them, resulting in poor productivity. In addition, it is necessary to maintain the assembled state of the stator core laminate formed by combining a number of sectors S2 in the assembled state by using the restraint member indicated by F in the drawing, which further deteriorates the productivity. It should be noted that the restraint member F is preliminarily formed with mounting bolt holes and the like. 13 to 15, the tooth portion is indicated by T and the outer peripheral portion is indicated by B.

[0004]

The punching patterns shown in FIGS. 13 and 14 have a poor material yield. Further, when a coil is wound around a stator core formed by laminating the stator core plates to complete the stator, it is difficult to separate the coil and the core when discarding the stator. According to the punching pattern of FIG. 15, although the material is effectively used, it takes a lot of man-hours to assemble the stator core and also requires a restraining member to maintain the assembled state.

The present invention has been made in view of the above circumstances, and it is an object of the present invention that the material yield when punching a stator core plate is good, and that when a completed stator is discarded, it can be easily separated by material. Moreover, it is to provide a stator core that can be easily assembled.

[0006]

Means for Solving the Problems A stator core according to the present invention includes a laminated tooth portion in which steel plates having a predetermined shape are laminated, and a compression molded body of magnetic powder that wraps and holds the outer periphery of the laminated tooth portion. It is characterized by In this stator core, since the laminated teeth portion is held by the compression molded body, the laminated teeth portion is relatively easily fixed in position and easy to manufacture. The stator core plate for forming the laminated tooth portion can be punched from the steel sheet with a good yield. Furthermore, the compression molded body is easily broken into pieces, and when the stator is discarded, the compression molded body is easily broken to separate the coil, the steel plate, and the magnetic powder.

In the case of the above stator core, the laminated tooth portion can be divided into a plurality of pieces, and each of the divided laminated tooth portions can be held by the compression molded body. In this case, since the laminated teeth portion is divided, the material yield at the time of punching the steel sheet is further improved.

Instead of the above divided laminated teeth portion, it is also possible to use a laminated teeth portion in which a long steel plate having a predetermined shape is spirally wound. In this case, not only the material yield at the time of stamping the steel sheet is improved, but also the lamination process is easily mechanized, and the stator core can be manufactured more easily.

When manufacturing the stator core of the present invention, a laminated tooth portion in which steel plates are laminated is formed by using a forming jig having a shape corresponding to a part of the inner space shape of the stator core, and the formed laminated tooth portion is used as a mold. A stator core can be manufactured by forming a compression molded body that is housed inside and filled with magnetic powder in the space inside the mold outside the housed laminated teeth portion to wrap and hold the outer periphery of the laminated teeth portion. According to this method, the stator core of the present invention can be easily manufactured.

In recent years, the recycling of industrial products has become an important issue. For example, in Japanese Unexamined Patent Publication No. 11-187600 and 2000-178030, the stator of the rotating machine is caulked and fixed to the rotating machine. Have been proposed to facilitate the disassembly of In this respect, according to the present invention,
Since the outer peripheral side of the laminated teeth portion is wrapped and held by the magnetic powder compression molded body, the compression molded body can be easily broken when the stator is disassembled (discarded), and by breaking it, the stator core The laminated tooth portion can be exposed. Therefore, when the stator is disassembled (discarded), the coil, the steel plate, and the magnetic powder are easily separated. Since the compression molded body formed of magnetic powder functions as a yoke for passing the magnetic force lines, it is possible to reduce the area of the outer peripheral portion of the stator core without impairing the strength and magnetic characteristics.
Therefore, the compression molded body can be easily disassembled (broken) and easily recycled.

[0011]

Embodiments of the present invention will be described below with reference to the drawings. [First Embodiment] FIG. 1 is a front view of a stator core 1 of an electric motor. A stator core 1 shown in the figure includes a laminated tooth portion 2 having a structure in which steel plates are laminated in a direction perpendicular to the plane of the drawing, and a cylindrical compression-molded tube 3 that encloses and holds the outer periphery of the laminated tooth portion 2. As shown in FIG. 2, the laminated tooth portion 2 has a connecting portion 4 which constitutes a part of an outer peripheral portion of the stator core 1.
The tooth portion 5 is formed by spirally winding a steel plate 6 having a long continuous shape. The long steel plate 6 may be a single ribbon-shaped one, but as shown in FIGS. 3 (a) and 3 (b), a plurality of long steel plates 6 are punched out into strips or strips. Can be used as an extension. (A) shows an example in which six long steel plates 6 are punched out from a substantially square steel plate, and (b) shows an example in which two long steel plates 6 are punched out from a long steel strip. It is immediately understood that the material yield is good and the material waste is small. The long steel plate 6 needs to be curved in-plane (Fig. 2
reference). Therefore, it is difficult to widen the width of the connecting portion 4. If the width of the connecting portion 4 is narrow, the magnetic resistance of the outer ring yoke becomes high. Therefore, from the viewpoint of magnetic characteristics, it is not preferable that the width of the connecting portion 4 is narrow. However, in this example, in order to mold the compression molding cylinder 3 with magnetic powder, as will be described later,
Even if the width of the connecting portion 4 is narrow, the magnetic resistance can be reduced by the compression molding cylinder 3. Therefore, it is possible to easily form the connecting portion 4 with a narrow width and to bend it without impairing the magnetic characteristics of the stator core. In addition, as a steel plate used as a material, an electromagnetic steel plate or a cold rolled steel plate can be used.

A forming jig 7 shown in FIG. 4 is used for spirally winding the long steel plate 6 to form the laminated tooth portion 2. The molding jig 7 has a cylindrical member 7b at the center of the rotary base 7a.
And a plurality of guide rods 7c are erected at positions surrounding the columnar member 7b. The guide rod 7c is arranged in a shape that matches the inner space shape formed between the adjacent tooth portions 5 of the stator core 1. Also, the cylindrical member 7b
Has a shape that matches the inner space shape surrounded by the tips of the tooth portions 5 of the stator core 1. As shown in FIG. 5, the long steel plate 6 is spirally wound around the forming jig 7 to form the laminated tooth portion 2. In the spiral winding step, the rotation base 7 a of the forming jig 7 is rotated to wind up the long steel plate 6, and the adjacent tooth portions 5 of the long steel plate 6 are wound.
The guide rods 7c are sequentially engaged between the (comb teeth), and the tips of the teeth portions 5 are brought into contact with the columnar member 7b for positioning. As a result, the long steel plate 6 is wound in a spiral shape easily, quickly and accurately. The cross-sectional shape and the number of the guide rods 7c can be set appropriately. The guide rods 7c may be inserted into all of the adjacent teeth 5, or the guide rods 7c may be inserted into each of the adjacent teeth 5.

Next, the compression molding process of the compression molding cylinder 3 will be described. As shown in FIG. 6, press die (lower die)
8 is provided with a ring-shaped cavity 8a for accommodating the laminated teeth portion 2, and a slot portion 8b for positioning the teeth portion 5 is provided on the inner peripheral side. FIG. 7 shows a state in which the laminated tooth portion 2 is set in the mold 8. In the figure, the molding space 8c of the compression molding cylinder 3 remains on the outer peripheral side of the laminated tooth portion 2. 8d in the figure
Is a mounting hole forming portion of the stator core. As shown in FIG. 8, the molding space 8c is filled with the magnetic powder 9 and then covered with an upper mold (not shown) for press molding. As the magnetic powder 9, used is an iron powder having a particle diameter of several tens of μm and a silica-based or phosphoric-acid-based insulating film having a film thickness of 10 nm to 100 nm attached thereto by a sol-gel method. After press molding, heat treatment is performed at about 400 ° C. to remove residual stress of iron powder.

In this way, the compression molding cylinder 3 is integrally molded on the outer peripheral side of the laminated teeth portion 2 to complete the stator core 1. The stator core 1 is wound in the next step to complete the stator. If a protrusion or a groove is provided on the outer peripheral side of the connection portion 4 in advance, the connection between the laminated tooth portion 2 and the compression molding cylinder 3 can be made stronger. In this example,
Since the compression molding cylinder 3 is designed to withstand a pressing force of about 100 MPa, it is relatively easy to make a magnetic powder compression molding (compression molding cylinder 3) by applying a pressing force of 100 MPa or more and impact at the time of disposal (decomposition). It can be broken apart. Since the exposed laminated teeth portion 2 has a weak connecting portion 4 and is easily deformed, the steel sheet, the coil, and the magnetic powder can be easily separated, and the recyclability is good.

[Embodiment 2] Next, an example in which the laminated tooth portion 2 has a divided structure will be described. FIG. 9 shows the teeth part 1
It is a top view which shows the material removal at the time of punching out 5. Since the steel plate 15 laminated in this example has no connecting portion, the tooth portion 1
Only 5 can be punched out in large numbers. There is very little material waste. The punched-out tooth portions 15 are laminated to form a required number of divided laminated tooth bodies 16 shown in FIG. The divided laminated teeth body 16 is welded, bonded,
Joining by means such as caulking is preferable because it facilitates the work. Next, the required number of divided laminated teeth bodies 16 are set in the same press die 18 as that used in Embodiment 1 (see FIG. 11), and the molding space 18c of the compression molded body is filled with magnetic powder. Then, the upper mold (not shown) is covered and press molding is performed. At this time, since the engaging projection 15a (see FIG. 10) formed on the back surface side of the tooth portion 15 is embedded in the compression molded body of magnetic powder, each divided laminated tooth portion 15 is firmly held by the compression molded body. To be done. In this case, the compression molded body serves as an outer ring yoke through which magnetic force passes. In the stator core of this example, the plurality of laminated stator cores 15 are connected and held by the compression molded body, so that the stator core can be easily manufactured. Also,
Since the compression molded body can be broken relatively easily, the stator can be disassembled relatively easily, and the materials can be easily separated.

[Other Example] The strength of the compression-molded cylinder made of the magnetic powder compression-molded body may be insufficient. In such a case, as shown in FIG. 12, the ring-shaped reinforcing member 32 is inserted into the magnetic powder compression molded body 33 by insert molding.
Can be embedded, and the strength of the compression molding cylinder 33 can be improved by insert molding the reinforcing member 32.

It is also possible to adopt a structure in which the laminated teeth portion having the core shape (see FIG. 13) described in the conventional example is held by the compression molding cylinder described in the first embodiment. Even in this case, since the compression molded body can be relatively easily broken and disassembled when the stator is discarded, the recyclability is improved.

[0018]

As described above, according to the stator core of the present invention, it is possible to improve the material yield when punching the stator core plate from the steel plate. Further, since the laminated teeth portion is held by the magnetic powder compression molding, the assembly process of the stator core is simplified. Moreover, since the stator can be broken relatively easily when it is discarded, it is easy to separate the materials, and the recyclability is excellent.

[Brief description of drawings]

FIG. 1 is a front view of a stator core according to a first embodiment.

FIG. 2 is a perspective view of a laminated tooth portion.

FIG. 3 is a plan view for explaining the material removal of the stator core plate, (a) is a case where a standard length material is used,
Shows the case where a hoop material is used.

FIG. 4 is a perspective view of a forming jig for a laminated tooth portion.

FIG. 5 is a front view illustrating a manner in which long steel plates are rolled up.

FIG. 6 is a front view of a mold.

FIG. 7 is a front view of a mold in which a laminated tooth portion is set.

FIG. 8 is a front view of a mold filled with magnetic powder.

FIG. 9 is a plan view illustrating material removal of a stator core plate.

FIG. 10 is a perspective view showing a divided laminated tooth body.

FIG. 11 is a front view of a mold in which a divided laminated tooth body is set.

FIG. 12 is a front view illustrating another example of the compression molding cylinder.

FIG. 13 is a diagram illustrating material removal of a stator core plate of a conventional example.

FIG. 14 is a diagram illustrating material removal of a stator core plate of a conventional example.

FIG. 15 is a diagram illustrating material removal of a conventional split stator core plate.

FIG. 16 is a front view illustrating a connection state of a conventional split stator core plate.

[Explanation of symbols]

1: Stator core 2: Laminated teeth part 3: Compression molded tube 4: Connection part 5: Teeth part 6: Long steel plate 7: Molding jig 8: Mold 9: Magnetic powder

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Toshimitsu Toshida             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. (72) Inventor Munehiro Kamiya             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. (72) Inventor Eiji Yanagida             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. F-term (reference) 5H002 AA06 AA07 AB06 AC07 AE02                       AE08                 5H615 AA01 AA03 BB01 BB07 BB14                       BB16 PP01 PP07 PP10 SS10                       SS11 SS13 SS24 SS44 TT04

Claims (4)

[Claims] 1. A stator core comprising a laminated tooth portion in which steel sheets having a predetermined shape are laminated, and a compression molded body of magnetic powder that wraps and holds the outer periphery of the laminated tooth portion. 2. The stator core according to claim 1, wherein each of the divided laminated tooth portions divided into a plurality is held by the compression molded body. 3. The stator core according to claim 1, wherein the laminated tooth portion is formed by spirally winding a long steel plate having a predetermined shape. 4. A laminated tooth portion in which steel plates are laminated is formed by using a forming jig having a shape that matches a part of the inner space shape of the stator core, and the formed laminated tooth portion is accommodated in a mold and accommodated. A method for manufacturing a stator core by filling a magnetic powder in a space outside a laminated tooth portion with magnetic powder to form a compression molded body that wraps and holds the outer periphery of the laminated tooth portion.