JP2004120827A - Motor using magnetic wedge, and its manufacturing method - Google Patents
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- JP2004120827A JP2004120827A JP2002277221A JP2002277221A JP2004120827A JP 2004120827 A JP2004120827 A JP 2004120827A JP 2002277221 A JP2002277221 A JP 2002277221A JP 2002277221 A JP2002277221 A JP 2002277221A JP 2004120827 A JP2004120827 A JP 2004120827A
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Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、高速に回転する電動機、特に磁性くさびを固定子のスロット内に用いた電動機のインバータ電圧波形の影響により生じるキャリア損失の低減に関するものである。
【０００２】
【従来の技術】
本発明に関連する従来特許は数多く出願されている（例えば、特許文献１〜３参照。）。
【０００３】
【特許文献１】
特開平７−１２３６２２号公報
【特許文献２】
特開平７−２２７０５３号公報
【特許文献３】
特開平８−１７２７４２号公報
【０００４】
その中で代表的な構成を図４および図５を用いて説明する。
図４において、１は固定子、２は固定子コア、３はスロット、４はティース、６は巻線、７はくさび、８はスロット肩部、９はテーパ部、１１は巻線の作る磁束である。
固定子１は電磁鋼板をスロット３およびティース４を金型にて打抜いた後、所望の積厚となるまで紙面に垂直な方向に積層し、その後カシメ等により固着して固定子コア２を構成し、該固定子コア２のスロット３には電気装荷手段となる巻線６を巻回し、該スロット３のスロット肩部８にはくさび７が打込み挿入されて成る構成である。
【０００５】
図４は図３に用いられるくさびの斜視図である。
このくさび７は図４に示すように磁性粉含有樹脂層１２をガラスクロス１３に塗布したものを多層に積層固化した板状の母材を、前記スロット肩部８の幅より若干大きく切り出した後、該スロット肩部８の幅に合わせて切削し、更に該スロット肩部８のテーパ部９に合わせて面取り加工を施し作られている。
その断面はスロット肩部９と相似形をしており、したがってくさび７はスロット肩部８にハンマー等で打込み挿入できるようになっている。
高速回転する電動機では一般にインダクタンスは小さい。これは、電動機の端子に加わる電圧値がインバータの出力電圧値により制限されており、高速回転を目的とした電動機では、逆起電力を抑えるために電気装荷手段となる巻線の巻回数を少なくした設計となるためである。そのため、インダクタンスは巻数の２乗に比例する値であり、高速回転する電動機ほどインダクタンスは小さくなる。
電動機をインバータにより駆動する場合、電動機端子に加わる電圧波形は細かく見るとキャリア周波数に比例した矩形波である。そのため、電動機に流れる電流はこの矩形波をした電圧波形に起因する三角波をしたリップル電流を含むこととなる。その大きさは電動機のインダクタンスが小さいほど大きな値となる。
このリップル電流は、高調波銅損及び高調波鉄損の原因であり、高速回転で用いられる電動機はリップル電流低減のために如何にしてインダクタンスを増やすかが課題となっていた。
図４において、巻線６の作るスロット３内を通る漏れ磁束１１は、スロット３内に位置する巻線６およびスロット肩部８を通る。スロット肩部８には磁性粉含有くさび７が打込まれており、この部位では磁束の流れ易さを表す透磁率が、前記くさび７が打込まれていない場合に比べて大幅に高くなっており、漏れ磁束１１は流れ易くなっている。そのため、巻線６の作る漏れ磁束１１の全体の量は、くさび７を設けることにより増加させることが出来、該くさび７を設けたことで
電動機のインダクタンスを増加させることが出来る。
以上述べたように、従来、高速回転する電動機ではリップル電流低減のためにインダクタンスを増大させる目的でスロット開口部に磁性粉含有くさびを打込んでいた。
【０００６】
【発明が解決しようとする課題】
ところが、上述した従来のくさびを打込む電動機においては、くさび７の断面形状をスロット肩部８の断面形状に合わせて製作する必要があり、ハンマー等で打込むことで挿入可能なほどの寸法精度を要求されていた。そのため、くさび７の製作は加工工数が多く、高価なものとなっていた。
また、くさび７の断面形状をスロット肩部８より小さくし、加工精度を下げると、挿入した際にスロット肩部８において、くさび７とティース４との間に空隙が生じることとなる。空隙が生じると、くさび７を打込み漏れインダクタンスを大きくする効果が薄れ、所望の増加を望めないという問題があった。
本発明は、これらの問題に鑑みてなされたものであり、くさびを用いた電動機において、容易にスロット肩部に挿入出来るほど断面形状を該スロット肩部に対して小さくし、且つ、くさびの加工精度を落としても、インダクタンスを小さく低下させることが無いくさび構造およびその製造方法を提供することを目的としたものである。
【０００７】
【課題を解決するための手段】
上記目的を達成するために、請求項１記載のくさびを用いた電動機の発明は、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機において、前記磁性くさびが、前記スロット肩部に挿入された磁性粉含有樹脂製磁性コアと、前記磁性コアと前記スロット肩部のティースとの隙間に充填した磁性粉含有樹脂と、で構成されたことを特徴とする。
以上の構成により、くさびをスロット肩部にハンマーで打込むという従来の不便な工程をなくすことが出来、安価に製作することが出来るようになる。
また、磁性コアの断面形状をスロット肩部の断面形状にきっちり合わせる必要が無いため、磁性コアの加工精度を下げることが出来、くさびの製作が安価に行え、しかも従来製品よりも大きなインダクタンスの増加が見込める。
請求項２記載のくさびを用いた電動機の発明は、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機において、前記磁性くさびを前記スロット肩部に挿入されて固化した磁性粉含有樹脂で構成したことを特徴とする。
以上の構成により、さらに請求項１の磁性粉含有樹脂製磁性コアをなくして、その代わりに磁性粉含有樹脂のみを充填固化させてくさびを構成したので、スロット肩部に隙間無く磁性粉含有くさびを設けることが出来、インダクタンスの増加が見込める。
請求項３記載の発明は、請求項１又は２記載の磁性くさびを用いた電動機において、前記磁性粉含有樹脂に含有される磁性粉が鉄紛であることを特徴とする。
以上の構成により、透磁率が高く且つ安価な材料でくさびを構成することが出来る。
請求項４記載の発明は、請求項１〜３のいずれか１項記載の磁性くさびを用いた電動機において、前記磁性粉含有樹脂の樹脂がエポキシ樹脂であることを特徴とする。
以上の構成により、機械強度と耐薬品強度が高く且つ入手し易い安価な材料でくさびを構成することが出来る。
【０００８】
請求項５記載の磁性くさびを用いた電動機の製造方法の発明は、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機の製造方法において、該スロット肩部に、磁性粉含有樹脂製磁性コアを挿入し、且つ、該磁性コアをスロット肩部に挿入する際、磁性粉含有樹脂を前記磁性コアとスロット肩部のティースとの隙間に充填する工程と、該充填した磁性粉含有樹脂をスロット肩部にて固化させる工程を有することを特徴とする。
以上の構成により、くさびをスロット肩部にハンマーで打込むという従来の不便な工程をなくすことが出来、安価に製作することが出来るようになる。
また、磁性コアの断面形状をスロット肩部の断面形状にきっちり合わせる必要が無いため、磁性コアの加工精度を下げることが出来、くさびの製作が安価に行える。
請求項６記載の磁性くさびを用いた電動機の製造方法の発明は、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機の製造方法において、 磁性粉含有樹脂を前記スロット肩部に充填する工程と、該充填した磁性粉含有樹脂を前記スロット肩部にて固化する工程を有することを特徴とする。
以上の構成により、磁性粉含有樹脂のみを充填固化させてくさびを構成したので、スロット肩部の形状に沿ったくさびを容易に構成でき、安価に製作でき、またインダクタンスの増加が見込める。
【０００９】
【発明の実施の形態】
次に本発明の第１の実施形態について、図１を参照して詳細に説明する。
図１は本発明の第１の実施形態に係るくさびを用いた電動機の断面図で、同図において、１は固定子、２は固定子コア、３はスロット、４はティース、５は磁性コア、６は巻線、７はくさび、８はスロット肩部、９はテーパ部、１０は磁性粉含有樹脂、１１は巻線の作る磁束である。
固定子１は電磁鋼板をスロット３およびティース４を金型にて打抜いた後、所望の積厚となるまで紙面に垂直な方向に積層すると共にカシメ等により固着して固定子コア２を構成し、該固定子コア２のスロット３には電気装荷手段となる巻線６を巻回し、該スロット３のスロット肩部８にはくさび７を設け構成した。
図２は図１に用いられるくさびの斜視図である。
くさび７は、図２に示すように、磁性粉含有樹脂層１２をガラスクロス１３に塗布したものを多層に積層固化した板状の母材を、該スロット肩部８の幅より若干小さい幅に切り出した後に、テーパ部９に沿う形に面取りを行い構成した磁性コア５を前記スロット肩部８に挿入し、且つ、該磁性コア５をスロット肩部８に挿入する際、磁性粉含有樹脂１０を前記磁性コア５とスロット肩部８のティース４との隙間に充填し、該充填した磁性粉含有樹脂１０をスロット肩部にて固化させ、前記磁性コア５と充填固化させた磁性粉含有樹脂１０とで構成した。
なお、本実施の形態では、磁性粉として平均粒径が１００μｍの鉄紛を用い、樹脂にはエポキシ樹脂を用いて構成した。
こうすることにより、くさび７をスロット肩部８にハンマーで打込むという工程をなくすことが出来、安価に製作することが出来る。
さらに、磁性コア５とスロット肩部８との隙間に磁性粉含有樹脂１０を充填固化させ、くさび７を構成することにより、スロット肩部８に隙間無く磁性粉含有くさび７を設けることが出来、インダクタンスの増加が見込める。
また、磁性コア５の断面形状をスロット肩部８の断面形状にきっちり合わせる必要が無いため、磁性コア５の加工精度を下げることが出来、くさび７の製作が安価に行え、しかも従来製品よりも大きなインダクタンスの増加が見込める。
また、本実施の形態では、磁性粉として鉄紛を用いたことにより、透磁率が高く且つ安価な材料でくさびを構成することが出来る。
また、本実施の形態では、樹脂としてエポキシ樹脂を用いたことにより、機械強度と耐薬品強度が高く且つ入手し易い安価な材料でくさびを構成することが出来る。
なお、本実施の形態では、磁性コア５の製作を上述のような方法で行っているが、大量に製作する際は、磁性粉含有樹脂を射出成形により成形することも出来る。
【００１０】
次に、本発明の第２の実施の形態を図３を用いて説明する。
図３は本発明の第２の実施形態に係るくさびを用いた電動機の断面図で、固定子形状および巻線等は図１と同様であるため説明を省略する。
第２の実施形態では、巻線６を保護する絶縁紙１４をスロット肩部８に設け、更に、磁性粉含有樹脂１０を該スロット肩部８に隙間無く充填した後、加熱することで固化させ、くさび７を形成した。本実施の形態では、実施の形態１で示した磁性粉含有樹脂１０を用いたため、パテ状になるまでしばらく放置して所望の粘度となった状態で、前記スロット肩部８に指で押込み充填した。
こうすることによりスロット肩部の形状に沿ったくさびを容易に構成でき、安価に製作できる。また、スロット肩部８に隙間無く磁性粉含有くさび７を設けることが出来、インダクタンスの増加が見込める。
【００１１】
【発明の効果】
以上説明したように、請求項１記載の発明によれば、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機において、前記磁性くさびが、前記スロット肩部に挿入された磁性粉含有樹脂製磁性コアと、前記磁性コアと前記スロット肩部のティースとの隙間に充填した磁性粉含有樹脂と、で構成されたことにより、くさびをスロット肩部にハンマーで打込むという従来の不便な工程をなくすことが出来、安価に製作することが出来るようになる。
また、磁性コアの断面形状をスロット肩部の断面形状にきっちり合わせる必要が無いため、磁性コアの加工精度を下げることが出来、くさびの製作が安価に行え、しかも従来製品よりも大きなインダクタンスの増加が見込める。
【００１２】
請求項２記載の発明によれば、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機において、前記磁性くさびを前記スロット肩部に挿入されて固化した磁性粉含有樹脂で構成したことにより、磁性粉含有樹脂製磁性コアの代わりに磁性粉含有樹脂のみを充填固化させてくさびを構成したので、スロット肩部に隙間無く磁性粉含有くさびを設けることが出来、インダクタンスの増加が見込める。
請求項３記載の発明によれば、請求項１又は２記載の磁性くさびを用いた電動機において、前記磁性粉含有樹脂に含有される磁性粉を鉄紛で構成したことにより、透磁率が高く且つ安価な材料でくさびを構成することが出来る。
請求項４記載の発明によれば、請求項１〜３のいずれか１項記載の磁性くさびを用いた電動機において、前記磁性粉含有樹脂の樹脂をエポキシ樹脂で構成したので、機械強度と耐薬品強度が高く且つ入手し易い安価な材料でくさびを構成することが出来る。
請求項５記載の磁性くさびを用いた電動機の製造方法の発明によれば、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機の製造方法において、該スロット肩部に、磁性粉含有樹脂製磁性コアを挿入し、且つ、該磁性コアをスロット肩部に挿入する際、磁性粉含有樹脂を前記磁性コアとスロット肩部のティースとの隙間に充填する工程と、該充填した磁性粉含有樹脂をスロット肩部にて固化させる工程を有することにより、くさびをスロット肩部にハンマーで打込むという従来の不便な工程をなくすことが出来、安価に製作することが出来るようになる。
また、磁性コアの断面形状をスロット肩部の断面形状にきっちり合わせる必要が無いため、磁性コアの加工精度を下げることが出来、くさびの製作が安価に行える。
【００１３】
請求項６記載の磁性くさびを用いた電動機の製造方法の発明によれば、電磁鋼板を打抜き積層して形成する固定子のスロット内に電気装荷手段となる巻線を巻回し、かつ前記スロット肩部に磁性くさびを備えて成る電動機の製造方法において、磁性粉含有樹脂を前記スロット肩部に充填する工程と、該充填した磁性粉含有樹脂を前記スロット肩部にて固化する工程を有することにより、磁性粉含有樹脂のみを充填固化させてくさびを構成したので、スロット肩部の形状に沿ったくさびを容易に構成でき、安価に製作でき、またインダクタンスの増加が見込める。
【図面の簡単な説明】
【図１】本発明の第１の実施形態に係るくさびを用いた電動機の断面図である。
【図２】図１の磁性コアの形状を示す斜視図である。
【図３】本発明の第２の実施形態に係るくさびを用いた電動機の断面図である。
【図４】従来公知のくさびを用いた電動機の断面図である。
【図５】図４の公知のくさびの形状を示す斜視図である。
【符号の説明】
１ 固定子
２ 固定子コア
３ スロット
４ ティース
５ 磁性コア
６ 巻線
７ くさび
８ スロット肩部
９ テーパ部
１０ 磁性粉含有樹脂
１１ 巻線の作る磁束
１２ 磁性粉含有樹脂層
１３ ガラスクロス
１４ 絶縁紙[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a motor rotating at a high speed, and more particularly to a motor using a magnetic wedge in a slot of a stator to reduce carrier loss caused by an inverter voltage waveform.
[0002]
[Prior art]
Many patents related to the present invention have been filed (for example, see Patent Documents 1 to 3).
[0003]
[Patent Document 1]
JP-A-7-123622 [Patent Document 2]
JP-A-7-227053 [Patent Document 3]
JP-A-8-172742
Among them, a representative configuration will be described with reference to FIGS.
In FIG. 4, 1 is a stator, 2 is a stator core, 3 is a slot, 4 is a tooth, 6 is a winding, 7 is a wedge, 8 is a slot shoulder, 9 is a tapered portion, and 11 is a magnetic flux generated by the winding. It is.
The stator 1 is formed by punching out a magnetic steel sheet from a slot 3 and a tooth 4 with a metal mold, and then laminating the magnetic steel sheet in a direction perpendicular to the paper surface until a desired thickness is obtained. A winding 6 serving as an electric loading means is wound around a slot 3 of the stator core 2, and a wedge 7 is driven into a slot shoulder 8 of the slot 3.
[0005]
FIG. 4 is a perspective view of the wedge used in FIG.
As shown in FIG. 4, the wedge 7 is obtained by cutting a plate-like base material obtained by applying a magnetic powder-containing resin layer 12 to a glass cloth 13 and laminating and solidifying it in a multilayer, slightly larger than the width of the slot shoulder 8. The slot shoulder 8 is cut in accordance with the width thereof, and is further chamfered in accordance with the tapered portion 9 of the slot shoulder 8.
Its cross-section is similar to the slot shoulder 9 so that the wedge 7 can be inserted into the slot shoulder 8 by hammering or the like.
In general, a motor rotating at high speed has a small inductance. This is because the voltage applied to the terminals of the motor is limited by the output voltage of the inverter, and in a motor intended for high-speed rotation, the number of turns of the winding serving as the electric loading means is reduced in order to suppress the back electromotive force. This is because the design is as follows. Therefore, the inductance is a value proportional to the square of the number of turns, and the higher the motor speed is, the smaller the inductance is.
When the motor is driven by the inverter, the voltage waveform applied to the motor terminal is a rectangular wave proportional to the carrier frequency when viewed in detail. Therefore, the current flowing through the motor includes a triangular-wave ripple current resulting from the rectangular-wave voltage waveform. The magnitude of the magnitude increases as the inductance of the motor decreases.
This ripple current is a cause of harmonic copper loss and harmonic iron loss, and it has been a problem how to increase the inductance of a motor used at high speed to reduce the ripple current.
In FIG. 4, the leakage magnetic flux 11 passing through the slot 3 created by the winding 6 passes through the winding 6 and the slot shoulder 8 located in the slot 3. A magnetic powder-containing wedge 7 is driven into the slot shoulder 8, and the magnetic permeability indicating the easiness of the flow of the magnetic flux is significantly higher in this portion than in the case where the wedge 7 is not driven. As a result, the leakage magnetic flux 11 flows easily. Therefore, the total amount of the leakage magnetic flux 11 generated by the winding 6 can be increased by providing the wedge 7, and the provision of the wedge 7 can increase the inductance of the electric motor.
As described above, conventionally, in a motor that rotates at a high speed, a magnetic powder-containing wedge is driven into a slot opening for the purpose of increasing inductance to reduce ripple current.
[0006]
[Problems to be solved by the invention]
However, in the above-described conventional wedge driving motor, it is necessary to manufacture the cross section of the wedge 7 in accordance with the cross section of the slot shoulder 8, and the dimensional accuracy is such that it can be inserted by driving with a hammer or the like. Was required. For this reason, the production of the wedge 7 requires a large number of processing steps and is expensive.
Also, if the cross-sectional shape of the wedge 7 is made smaller than the slot shoulder 8 to reduce the processing accuracy, a gap is created between the wedge 7 and the teeth 4 at the slot shoulder 8 when inserted. When a gap is formed, the effect of driving the wedge 7 to increase the leakage inductance is weakened, and there is a problem that a desired increase cannot be expected.
The present invention has been made in view of these problems, and in a motor using a wedge, a cross-sectional shape of the electric motor using the wedge is made smaller than that of the slot shoulder so as to be easily inserted into the slot shoulder, and the wedge is processed. It is an object of the present invention to provide a wedge structure that does not cause a small decrease in inductance even if accuracy is reduced, and a method for manufacturing the same.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, an invention of a motor using a wedge according to claim 1 is configured such that a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and In a motor having a magnetic wedge at a slot shoulder, the magnetic wedge fills a gap between a magnetic core made of a magnetic powder-containing resin inserted into the slot shoulder and a tooth between the magnetic core and the teeth at the slot shoulder. And a magnetic powder-containing resin.
With the above configuration, the conventional inconvenient process of hammering the wedge into the slot shoulder with a hammer can be eliminated, and the wedge can be manufactured at low cost.
Also, since it is not necessary to match the cross-sectional shape of the magnetic core exactly to the cross-sectional shape of the shoulder of the slot, the processing accuracy of the magnetic core can be reduced, wedges can be manufactured at low cost, and the inductance increases more than conventional products. Can be expected.
According to a second aspect of the present invention, there is provided an electric motor using a wedge, wherein a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and a magnetic wedge is provided at a shoulder of the slot. The magnetic wedge is characterized in that the magnetic wedge is formed of a magnetic powder-containing resin which is inserted into the slot shoulder and solidified.
With the above structure, the magnetic powder-containing resin magnetic core according to claim 1 is further eliminated, and instead the magnetic powder-containing resin is filled and solidified to form the wedge, so that the magnetic powder-containing wedge has no gap at the slot shoulder. And an increase in inductance can be expected.
According to a third aspect of the present invention, in the electric motor using the magnetic wedge according to the first or second aspect, the magnetic powder contained in the magnetic powder-containing resin is iron powder.
With the above configuration, the wedge can be made of a material having high magnetic permeability and low cost.
According to a fourth aspect of the present invention, in the electric motor using the magnetic wedge according to any one of the first to third aspects, the resin of the magnetic powder-containing resin is an epoxy resin.
With the above configuration, the wedge can be made of an inexpensive material that has high mechanical strength and chemical resistance and is easily available.
[0008]
According to a fifth aspect of the present invention, there is provided a method of manufacturing a motor using a magnetic wedge, wherein a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel plate, and the slot shoulder portion is provided. In a method of manufacturing an electric motor having a magnetic wedge, a magnetic core made of a resin containing magnetic powder is inserted into the shoulder of the slot, and when the magnetic core is inserted into the shoulder of the slot, the resin containing the magnetic powder is removed by the magnetic material. The method includes a step of filling the gap between the core and the teeth of the slot shoulder, and a step of solidifying the filled magnetic powder-containing resin at the slot shoulder.
With the above configuration, the conventional inconvenient process of hammering the wedge into the slot shoulder with a hammer can be eliminated, and the wedge can be manufactured at low cost.
Further, since it is not necessary to exactly match the cross-sectional shape of the magnetic core with the cross-sectional shape of the slot shoulder, the processing accuracy of the magnetic core can be reduced, and the wedge can be manufactured at low cost.
According to a sixth aspect of the present invention, there is provided a method for manufacturing a motor using a magnetic wedge, wherein a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and the slot shoulder portion is provided. A method of manufacturing a motor having a magnetic wedge, comprising: filling a magnetic powder-containing resin into the slot shoulder; and solidifying the filled magnetic powder-containing resin at the slot shoulder. I do.
With the above configuration, since the wedge is formed by filling and solidifying only the resin containing the magnetic powder, the wedge along the shape of the slot shoulder can be easily configured, can be manufactured at low cost, and an increase in inductance can be expected.
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, a first embodiment of the present invention will be described in detail with reference to FIG.
FIG. 1 is a cross-sectional view of a motor using a wedge according to a first embodiment of the present invention, in which 1 is a stator, 2 is a stator core, 3 is a slot, 4 is a tooth, and 5 is a magnetic core. , 6 are windings, 7 is a wedge, 8 is a slot shoulder, 9 is a tapered portion, 10 is a resin containing magnetic powder, and 11 is a magnetic flux generated by the winding.
The stator 1 is formed by punching a slot 3 and a tooth 4 from a magnetic steel sheet using a metal mold, and then laminating the magnetic steel sheet in a direction perpendicular to the paper until a desired thickness is obtained, and fixing the stator 1 by caulking or the like to form a stator core 2. A winding 6 serving as an electric loading means is wound around the slot 3 of the stator core 2, and a wedge 7 is provided on a slot shoulder 8 of the slot 3.
FIG. 2 is a perspective view of the wedge used in FIG.
As shown in FIG. 2, the wedge 7 is formed by laminating and solidifying a magnetic powder-containing resin layer 12 applied to a glass cloth 13 in multiple layers to a width slightly smaller than the width of the slot shoulder 8. After cutting out, the magnetic core 5 formed by chamfering along the tapered portion 9 is inserted into the slot shoulder 8, and when the magnetic core 5 is inserted into the slot shoulder 8, the magnetic powder-containing resin 10 Is filled in the gap between the magnetic core 5 and the teeth 4 of the slot shoulder portion 8, and the filled magnetic powder-containing resin 10 is solidified at the slot shoulder portion, and the magnetic powder-containing resin filled and solidified with the magnetic core 5. And 10.
In this embodiment, iron powder having an average particle diameter of 100 μm is used as the magnetic powder, and epoxy resin is used as the resin.
By doing so, the step of hammering the wedge 7 into the slot shoulder 8 can be eliminated, and it can be manufactured at low cost.
Furthermore, by filling and solidifying the magnetic powder-containing resin 10 in the gap between the magnetic core 5 and the slot shoulder 8 and forming the wedge 7, the magnetic powder-containing wedge 7 can be provided in the slot shoulder 8 without a gap, An increase in inductance can be expected.
Further, since there is no need to exactly match the cross-sectional shape of the magnetic core 5 with the cross-sectional shape of the slot shoulder 8, the processing accuracy of the magnetic core 5 can be reduced, the wedge 7 can be manufactured at a lower cost, and moreover than conventional products. A large increase in inductance can be expected.
Further, in the present embodiment, since the iron powder is used as the magnetic powder, the wedge can be made of a material having high magnetic permeability and low cost.
Further, in the present embodiment, since the epoxy resin is used as the resin, the wedge can be made of an inexpensive material that has high mechanical strength and chemical resistance and is easily available.
In the present embodiment, the magnetic core 5 is manufactured by the above-described method. However, when the magnetic core 5 is manufactured in large quantities, a resin containing a magnetic powder can be formed by injection molding.
[0010]
Next, a second embodiment of the present invention will be described with reference to FIG.
FIG. 3 is a cross-sectional view of an electric motor using a wedge according to a second embodiment of the present invention.
In the second embodiment, an insulating paper 14 for protecting the winding 6 is provided on the slot shoulder 8, and the magnetic powder-containing resin 10 is filled into the slot shoulder 8 without gaps, and then solidified by heating. , A wedge 7 was formed. In the present embodiment, since the magnetic powder-containing resin 10 shown in the first embodiment is used, it is left standing for a while until it becomes a putty-like shape and a desired viscosity is reached. did.
By doing so, a wedge along the shape of the slot shoulder can be easily formed and can be manufactured at low cost. In addition, the magnetic powder-containing wedge 7 can be provided in the slot shoulder 8 without any gap, and an increase in inductance can be expected.
[0011]
【The invention's effect】
As described above, according to the first aspect of the present invention, a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and a magnetic wedge is formed on the slot shoulder. Wherein the magnetic wedge is a magnetic powder-containing resin magnetic core inserted into the slot shoulder, and a magnetic powder-containing resin filled in a gap between the magnetic core and the teeth of the slot shoulder. , The conventional inconvenient process of hammering the wedge into the slot shoulder with a hammer can be eliminated, and it can be manufactured at low cost.
Also, since it is not necessary to match the cross-sectional shape of the magnetic core exactly to the cross-sectional shape of the shoulder of the slot, the processing accuracy of the magnetic core can be reduced, wedges can be manufactured at low cost, and the inductance increases more than conventional products. Can be expected.
[0012]
According to the second aspect of the present invention, there is provided an electric motor in which a winding serving as an electric loading means is wound in a slot of a stator formed by stamping and laminating an electromagnetic steel sheet, and a magnetic wedge is provided at a shoulder of the slot. Since the magnetic wedge is formed of the magnetic powder-containing resin that is inserted into the slot shoulder and solidified, instead of the magnetic core made of the magnetic powder-containing resin, only the magnetic powder-containing resin is filled and solidified to form the wedge. In addition, the magnetic powder-containing wedge can be provided without any gap at the slot shoulder, and an increase in inductance can be expected.
According to the third aspect of the present invention, in the electric motor using the magnetic wedge according to the first or second aspect, the magnetic powder contained in the magnetic powder-containing resin is made of iron powder, so that the magnetic permeability is high and The wedge can be made of an inexpensive material.
According to the fourth aspect of the present invention, in the electric motor using the magnetic wedge according to any one of the first to third aspects, the resin of the magnetic powder-containing resin is made of an epoxy resin, so that mechanical strength and chemical resistance are improved. The wedge can be made of an inexpensive material that has high strength and is easily available.
According to the invention of the method for manufacturing a motor using a magnetic wedge according to claim 5, a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and the slot shoulder is provided. In the method for manufacturing a motor comprising a magnetic wedge in a portion, a magnetic core made of a magnetic powder-containing resin is inserted into the slot shoulder, and when the magnetic core is inserted into the slot shoulder, the magnetic powder-containing resin is Hammering the wedge into the slot shoulder by having a step of filling the gap between the magnetic core and the teeth of the slot shoulder, and a step of solidifying the filled magnetic powder-containing resin at the slot shoulder. Conventional inconvenient steps can be eliminated, and the device can be manufactured at low cost.
Further, since it is not necessary to exactly match the cross-sectional shape of the magnetic core with the cross-sectional shape of the slot shoulder, the processing accuracy of the magnetic core can be reduced, and the wedge can be manufactured at low cost.
[0013]
According to the method of manufacturing a motor using a magnetic wedge according to claim 6, a winding serving as an electric loading means is wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and the slot shoulder is provided. A method of manufacturing a motor comprising a magnetic wedge in a portion, comprising the steps of: filling a magnetic powder-containing resin into the slot shoulder, and solidifying the filled magnetic powder-containing resin at the slot shoulder. Since the wedge is formed by filling and solidifying only the magnetic powder-containing resin, the wedge along the shape of the slot shoulder can be easily formed, can be manufactured at low cost, and an increase in inductance can be expected.
[Brief description of the drawings]
FIG. 1 is a sectional view of a motor using a wedge according to a first embodiment of the present invention.
FIG. 2 is a perspective view showing a shape of a magnetic core of FIG. 1;
FIG. 3 is a sectional view of a motor using a wedge according to a second embodiment of the present invention.
FIG. 4 is a cross-sectional view of a motor using a conventionally known wedge.
FIG. 5 is a perspective view showing the shape of the known wedge of FIG. 4;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Stator 2 Stator core 3 Slot 4 Teeth 5 Magnetic core 6 Winding 7 Wedge 8 Slot shoulder 9 Tapered part 10 Magnetic powder containing resin 11 Magnetic flux made by winding 12 Magnetic powder containing resin layer 13 Glass cloth 14 Insulating paper
Claims (6)
前記磁性くさびが、前記スロット肩部に挿入された磁性粉含有樹脂製磁性コアと、前記磁性コアと前記スロット肩部のティースとの隙間に充填した磁性粉含有樹脂と、で構成されたことを特徴とする磁性くさびを用いた電動機。An electric motor comprising a winding serving as an electric loading means wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and comprising a magnetic wedge at the slot shoulder.
The magnetic wedge is formed of a magnetic core made of a magnetic powder-containing resin inserted into the slot shoulder, and a magnetic powder-containing resin filled in a gap between the magnetic core and the teeth of the slot shoulder. An electric motor using a magnetic wedge.
前記磁性くさびが、前記スロット肩部に挿入されて固化した磁性粉含有樹脂で構成されたことを特徴とする磁性くさびを用いた電動機。An electric motor comprising a winding serving as an electric loading means wound in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and comprising a magnetic wedge at the slot shoulder.
An electric motor using a magnetic wedge, wherein the magnetic wedge is made of a magnetic powder-containing resin that is inserted into the shoulder of the slot and solidified.
該スロット肩部に、磁性粉含有樹脂製磁性コアを挿入し、且つ、該磁性コアをスロット肩部に挿入する際、磁性粉含有樹脂を前記磁性コアとスロット肩部のティースとの隙間に充填する工程と、
該充填した磁性粉含有樹脂をスロット肩部にて固化させる工程を有することを特徴とする磁性くさびを用いた電動機の製造方法。A method for manufacturing an electric motor comprising: winding a winding serving as an electric loading means in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and including a magnetic wedge at the slot shoulder.
When a magnetic core made of a magnetic powder-containing resin is inserted into the slot shoulder, and when the magnetic core is inserted into the slot shoulder, the magnetic powder-containing resin fills the gap between the magnetic core and the teeth at the slot shoulder. The process of
A method for manufacturing a motor using a magnetic wedge, comprising a step of solidifying the filled magnetic powder-containing resin at a slot shoulder.
該スロット肩部に、磁性粉含有樹脂を充填する工程と、
該充填した磁性粉含有樹脂を前記スロット肩部にて固化する工程を有することを特徴とする磁性くさびを用いた電動機の製造方法。A method for manufacturing an electric motor comprising: winding a winding serving as an electric loading means in a slot of a stator formed by punching and laminating an electromagnetic steel sheet, and including a magnetic wedge at the slot shoulder.
Filling the slot shoulder with a magnetic powder-containing resin;
A method for manufacturing a motor using a magnetic wedge, comprising a step of solidifying the filled magnetic powder-containing resin at the shoulder of the slot.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| JP2002277221A JP4168245B2 (en) | 2002-09-24 | 2002-09-24 | Electric motor using magnetic wedge and method for manufacturing the same |
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| Application Number | Priority Date | Filing Date | Title |
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| JP2002277221A JP4168245B2 (en) | 2002-09-24 | 2002-09-24 | Electric motor using magnetic wedge and method for manufacturing the same |
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| JP2004120827A true JP2004120827A (en) | 2004-04-15 |
| JP4168245B2 JP4168245B2 (en) | 2008-10-22 |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2017158379A (en) * | 2016-03-04 | 2017-09-07 | 株式会社日立製作所 | Rotary electric machine |
| US9979248B2 (en) | 2015-06-29 | 2018-05-22 | General Electric Company | Short circuit fault tolerant permanent magnet machine |
| EP3703228A4 (en) * | 2017-10-26 | 2021-07-21 | Hitachi Industrial Products, Ltd. | Rotary electric machine and electrical motor vehicle provided with same |
-
2002
- 2002-09-24 JP JP2002277221A patent/JP4168245B2/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9979248B2 (en) | 2015-06-29 | 2018-05-22 | General Electric Company | Short circuit fault tolerant permanent magnet machine |
| JP2017158379A (en) * | 2016-03-04 | 2017-09-07 | 株式会社日立製作所 | Rotary electric machine |
| EP3703228A4 (en) * | 2017-10-26 | 2021-07-21 | Hitachi Industrial Products, Ltd. | Rotary electric machine and electrical motor vehicle provided with same |
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| Publication number | Publication date |
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| JP4168245B2 (en) | 2008-10-22 |
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