JP2005185014A - Spiral core of rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the spiral core of a rotary electric machine capable of easily attaining magnetic performance or rigidity equivalent to that of a core formed by laminating thin electromagnetic steel plates. <P>SOLUTION: A pulling force and a bending force are imparted while rolling out the yoke part 14 of a stripe core material 12 and the stripe core materials 12 are laminated spirally to form a spiral core 20. Each gap S occurring at the time of forming the spiral core 20 is filled with magnetic powder 24 thus recovering magnetic performance and rigidity. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a spirally wound core of a rotating electrical machine that can easily obtain the same magnetic performance and / or equivalent core rigidity as a spirally wound core of a rotating electrical machine, in particular, a core formed by laminating thin electromagnetic steel sheets. Concerning core improvements.

  Conventionally, a rotating electrical machine that functions as a motor or a generator is used as a pollution-free power source when the motor is driven, and as an effective energy use source during regenerative power generation. Among such rotating electric machines, for example, an inner rotor type rotating electric machine includes a stator core fixed to the inner peripheral side of a housing and a rotor that is rotatably supported on the inner peripheral side of the stator core. For example, the stator core has a cylindrical shape, and slots for inserting windings are formed at equal intervals along the inner periphery. In general, such a stator core is configured by laminating a plurality of thin donut-shaped electromagnetic steel plates in the rotation axis direction in order to suppress the generation of eddy currents.

  However, a thin donut-shaped electromagnetic steel sheet needs to be manufactured from a thin steel sheet used as a material for the electromagnetic steel sheet by punching press processing or the like. In this case, a large amount of residual portions (doughnut-shaped outer peripheral portion and donut-shaped inner diameter portion) generated as a result of the punching are generated, resulting in an increase in material cost. That is, a stator core of a type in which a plurality of thin donut-shaped electromagnetic steel sheets are stacked has a problem in that manufacturing efficiency is poor.

  Therefore, for example, as shown in FIG. 7, a belt-like core material 12 in which slot portions 10 into which windings (coils) are inserted is formed at equal intervals in the width direction is prepared, and a yoke portion 14 of the belt-like core material 12 is prepared. (The portion other than the tooth portion 16 forming the slot) is rolled by the non-uniform pressure roller 18 and a tensile force and a bending force are applied as shown in FIG. The band-shaped core material 12 is gradually bent to be longer. As a result, a method of forming a spirally wound core 20 wound spirally as shown in FIG. 8 has been proposed.

  In this case, as is clear from FIG. 7, the strip-shaped core material 12 can minimize the remaining portion at the time of manufacturing the strip-shaped core material 12 by performing the punching process by alternately arranging the teeth portions 16. Therefore, the material cost can be reduced. That is, it becomes possible to improve manufacturing efficiency (for example, refer patent document 1). The spirally wound core 20 can also be manufactured by forcibly bending the band-shaped core material 12 in the plane direction of the band-shaped core material 12.

JP 2000-224817 A

  However, as described above, even when the non-uniform pressure roller 18 is used to form the spirally wound core 20, the spirally wound core 20 is forcibly bent in the plane direction of the elongated core material 12. Even when 20 is formed, the yoke portion 14 is thinner than the tooth portion 16. That is, as shown in FIG. 9, the completed spirally wound core 20 has gaps S between the winding layers of the yoke portion 14 when the spirally wound core 20 is viewed in the axial cross section. When the gap S occurs, the space factor of the spirally wound core 20 decreases, and the magnetic performance decreases. As a result, there arises a problem that the output of the rotating electrical machine is reduced. Further, when the spirally wound core 20 is to be fixed by the annular housing 22 due to the presence of the gap S, there is a problem that the fixing force is reduced due to the presence of the gap S. Furthermore, the belt-like core members 12 of the respective wound layers laminated spirally by the gap S can move up and down, which causes a problem that vibrations and abnormal noise are generated in the rotating electrical machine. In other words, by adopting a spiral wound core, the material cost can be reduced, that is, the production efficiency can be improved. There was a problem that.

  Accordingly, the present invention has been made to solve at least one of the above-described problems, and a rotating electrical machine that can easily obtain magnetic performance equivalent to a core formed by laminating thin electromagnetic steel sheets. An object of the present invention is to provide a spiral wound core. It is another object of the present invention to provide a spirally wound core of a rotating electrical machine that can easily obtain a core rigidity equivalent to a core formed by laminating thin plate-shaped electromagnetic steel sheets.

  The present invention relates to a spirally wound core of a rotating electrical machine formed by spirally winding and laminating a strip-shaped core material having slot portions formed at equal intervals on one end side in the width direction. It is characterized in that a magnetic material is filled in the axial gap of the spirally wound core accompanying the thinning of the outer circumferential side with respect to the inner circumferential side of the spirally wound core that is generated by winding the spirally wound core.

  According to this structure, the clearance gap which a spiral winding core has can be excluded, and the whole core can be made into the lump of a magnetic body. As a result, the magnetic performance can be easily recovered to the same level as that of a core formed by laminating thin electromagnetic steel plates. Moreover, the rigidity of the spirally wound core can be easily restored to the same level as that of a core formed by laminating thin electromagnetic steel sheets by eliminating the gap. Further, fluttering between the layers is suppressed, which can contribute to suppression of vibration and abnormal noise.

  Moreover, the present invention is characterized in that, in the above-described configuration, the magnetic substance is a magnetic powder, and the magnetic powder is filled in each winding interlayer gap of a spirally wound belt-like core material.

  In this case, it is possible to easily improve the filling rate of the magnetic material in the gap between the winding layers of the belt-shaped core material, and the magnetic performance is easily restored to the same level as the core formed by laminating thin plate-shaped electrical steel sheets. can do.

  Further, the present invention is characterized in that, in the above configuration, the magnetic powder is filled in each winding interlayer gap together with an adhesive.

  In this case, for example, an epoxy-based adhesive can be used as the adhesive, and the belt-like core laminated in a spiral shape while recovering the magnetic performance to the same level as the core formed by laminating thin electromagnetic steel plates. It is possible to securely and firmly fix the wound layers of the material.

  Further, the present invention is the above configuration, wherein the magnetic body is a dust core, and the dust core is a collective gap formed as a result of closely contacting each winding interlayer gap formed on the spirally wound belt-like core material It is characterized by being attached to.

  Here, the collective gap is a spiral winding by pressing each winding interlayer gap formed in the spirally wound belt-shaped core material from, for example, the vertical direction (stacking direction) and closely contacting the gap portion of the belt-shaped core material. It is a space formed above and / or below one of the cores. Then, the dust core molded in the same shape as the formed gap is fixed with an adhesive or the like. In this case, the magnetic properties of the closely contacted portion of the belt-like core material are improved satisfactorily, and further, the density of the dust core can be easily improved. It can be easily recovered to the same level as a core formed by stacking steel plates.

  Moreover, the present invention is characterized in that, in the above configuration, the magnetic body is a magnetic wire, and the magnetic wire is filled in each winding interlayer gap of the spirally wound belt-like core material.

  Here, the magnetic fine wire is, for example, an iron fine wire. In this case, the magnetic thin wire can be easily inserted into the gap portion by a winding machine or the like, and the magnetic performance of the spirally wound core is formed by laminating thin electromagnetic steel plates with easy equipment and It can be restored to the same level. In addition, by using a magnetic wire, the skin effect can be obtained at the portion where the magnetic wire is inserted, and eddy current loss can be reduced. As a result, the efficiency of the rotating electrical machine can be improved. In this case, one magnetic thin wire may be wound, or a plurality of magnetic thin wires may be wound.

  Moreover, the present invention is characterized in that, in the above configuration, a cooling connection portion is provided at an end portion of the magnetic wire.

  Here, it is desirable to form the cooling connection portion at the start end portion or the end end portion of the magnetic fine wire, or both. Moreover, the cooling part to which the cooling connection part is connected is arbitrary as long as it is lower than the core temperature at the time of driving the rotating electrical machine. In this way, by connecting the cooling connection portion to the cooling portion, the heat generated in the spirally wound core can be easily dissipated through the magnetic wire filled in the gap of the spirally wound core.

  According to this configuration, the spiral wound core can be cooled while recovering the magnetic performance of the spiral wound core to a level equivalent to that of a core formed by laminating thin electromagnetic steel sheets, thereby improving the performance of the rotating electrical machine. Can contribute.

  Hereinafter, embodiments of the present invention (hereinafter referred to as embodiments) will be described with reference to the drawings. In the present embodiment, a stator core of an inner rotor type rotating electrical machine will be described as an example.

Embodiment 1. FIG.
FIG. 1 is an explanatory diagram illustrating the configuration of the spirally wound core according to the first embodiment. FIG. 1A shows a spirally wound core 20 before the processing of the first embodiment, that is, as shown in FIG. 7, the slot portions 10 into which windings are inserted are formed at equal intervals in the width direction. Preparing the strip-shaped core material 12 and applying a tensile force and a bending force while rolling the yoke portion 14 (a portion other than the teeth portion forming the slot) of the strip-shaped core material 12 with the non-uniform pressure roller 18. Thus, the spirally wound core 20 as shown in FIG. 8 is formed. In this case, as shown in FIG. 1A, when wound, the thickness on the outer peripheral side becomes thinner than the thickness on the inner peripheral side, and a gap S is generated. As described above, the gap S becomes a spatial gap, which causes a decrease in magnetic performance and a decrease in rigidity.

  Therefore, in the first embodiment, as shown in FIG. 1B, the magnetic powder 24 is filled as the magnetic material in each of the gaps S generated by laminating the belt-like core material 12 in a spiral shape. Yes. The magnetic powder 24 is, for example, fine particles of a ferromagnetic material such as iron. For example, the magnetic powder 24 can be press-fitted into the gap S by a method similar to the injection molding method. By filling the gap S with the magnetic powder 24, it can be considered that there is no gap between the strip-like core material 12 of the spirally wound core 20 formed by winding. That is, it can be made into a shape equivalent to a core formed by laminating thin magnetic steel sheets (hereinafter, this core is referred to as a laminated core with respect to the spiral wound core). As a result, the magnetic performance of the spirally wound core 20 filled with the magnetic powder 24 can be recovered to the same level as that of the conventional laminated core. Further, by filling the gap S with the magnetic powder 24, the rigidity of the entire core can be recovered to the same level as that of the conventional laminated core. Furthermore, flapping of the strip-shaped core material 12 forming the wound layer is eliminated by eliminating the gap S, and vibration of the rotating electrical machine and generation of abnormal noise can be prevented.

  FIG. 2 shows a conceptual manufacturing method of the spirally wound core 26 filled with the magnetic powder 24 shown in FIG.

  For example, the spirally wound core 20 as shown in FIG. 8 created by the method of FIG. 7 is set, for example, in a core storage type of a powder injection device (not shown). This core storage type has a shape that is equal to or slightly larger than the outer diameter of the spirally wound core 20. Note that the spirally wound core 20 is preliminarily subjected to a fixing process such as caulking so that the spiral shape does not collapse. After the spirally wound core 20 is set in the core storage type, the spirally wound core 20 is pressed and covered with an annular block 28 from above in order to prevent the magnetic powder 24 from scattering when the magnetic powder 24 is injected. In this state, the magnetic powder 24 is injected from around the spirally wound core 20, and the magnetic powder 24 is filled and pressed into the gap S formed in the spirally wound core 20. After filling a predetermined amount of the magnetic powder 24, the spirally wound core 20 is pressed using the block 28, the filled magnetic powder 24 is compressed, removed from the core storage mold, and the spirally wound core 26 is completed. The completed spirally wound core 26 holds the magnetic powder 24 filled in the spirally wound core 26 by holding the periphery with an annular housing 22 (see FIG. 9). Of course, the magnetic powder 24 may be held by hardening the outer peripheral surface of the spirally wound core 26 with resin or the like.

  When forming the spirally wound core 26 according to the first embodiment, it is desirable to press-fit the magnetic powder 24 directly. For example, an epoxy adhesive or the like is used as a binder and the gap S is formed together with the magnetic powder 24. It is possible to firmly and surely fix the belt-like core material 12 forming the spirally wound core 26 between the winding layers, thereby forming the spirally wound core 26 with higher reliability. it can.

Embodiment 2. FIG.
FIG. 3 shows another form of the spirally wound core 30. FIG. 3A shows the spirally wound core 20 before the processing of the second embodiment, that is, the spirally wound core 20 having the gap S. In the second embodiment, only the thinned yoke portion 14 of the spirally wound core 20 having the gap S is pressed in advance from above and below in the axial direction of the spirally wound core 20 so that the portions of each gap S are brought into close contact with each other. As shown in b), a space in which the gaps S are gathered, that is, a collective gap P is formed above and / or below one of the spirally wound cores 20.

  At this time, as shown in FIG. 2, the yoke portion 14 may be pressed by an annular block 28 or by a roller that rolls the yoke portion 14. At this time, the gap S can be gathered in a balanced manner on the upper and lower surfaces of the spirally wound core 20 by pressing with equal pressure from above and below. Of course, either the upper surface or the lower surface may be used.

  By the way, the collective gap P formed by gathering the gaps S can be recognized in advance based on the number of turns of the spirally wound core 20 and the rolled state of the yoke portion 14. Therefore, in the second embodiment, the magnetic powder as shown in FIG. 3C is pressed and the powder magnetic core 32 is molded and fixed to the gathering gap P with an adhesive or the like.

  In this case, a high magnetic performance can be obtained in the portion of the band-shaped core material 12 that is in close contact. On the other hand, since the dust core 32 is also compressed at a high density, high magnetic performance can be easily obtained. As a result, the entire spirally wound core 30 to which the dust core 32 is fixed has the same shape as the conventional laminated core, and the same level of magnetic properties and rigidity can be easily obtained. In addition, flapping of the strip-shaped core material 12 forming the wound layer is eliminated by eliminating the gap S, and vibration of the rotating electrical machine and generation of abnormal noise can be prevented.

  In the case of the spirally wound core 30 of the second embodiment, the use of the powder magnetic core 32 facilitates higher density and better magnetic properties than when the magnetic powder 24 is filled as in the spirally wound core 26 of the first embodiment. Performance can be obtained. On the other hand, in the case of the spirally wound core 26 having the configuration of the first embodiment, only the magnetic powder 24 is filled in the gaps S. Therefore, the axial size can be appropriately selected, but the spiral of the second embodiment. In the case of the wound core 30, the gap S of the yoke portion 14 is gathered, that is, deformed so as to gather the gap S on the outer peripheral portion of the core, so that it is not suitable for a spiral wound core having a large axial size. Therefore, it is desirable to select an appropriate structure according to the required axial size of the spirally wound core. In addition, when adopting the structure of the second embodiment, it is possible to increase the size in the axial direction by stacking a plurality of small-sized spirally wound cores 30 in the axial direction. In this case, since the plurality of spirally wound cores 30 are stacked, a key groove or the like is provided on the outer peripheral surface of the spirally wound core 30 so that the arrangement of the teeth portions 16 can be maintained in the axial direction so that the teeth can be easily positioned. It is desirable to keep it.

Embodiment 3. FIG.
FIG. 4 shows a spirally wound core 34 similar to the spirally wound core 26 of the first embodiment. Similar to the spirally wound core 26 of the first embodiment, the spirally wound core 34 of the third embodiment is filled with a magnetic material between the winding layers of the spirally wound belt-like core material 12. However, in the case of the third embodiment, the magnetic body is the magnetic wire 36. In this case, the magnetic wire 36 can be easily wound and inserted into the gap S by using a conventional winding machine or the like. Of course, at this time, the magnetic thin wire 36 to be wound may be one continuous wire or a wire divided into a plurality of wires.

  Even when the magnetic thin wire 36 is used, the gap S generated by the spiral winding can be easily and surely filled. Even in the case of using the spiral wound core 34 as in the first embodiment, a substantial shape is conventionally obtained. Thus, it is possible to obtain the same magnetic performance and rigidity as those of the conventional laminated core. In addition, flapping of the strip-shaped core material 12 forming the wound layer is eliminated by eliminating the gap S, and vibration of the rotating electrical machine and generation of abnormal noise can be prevented. When the magnetic thin wire 36 is used, it is possible to obtain a skin effect at the position where the magnetic thin wire 36 is disposed, and the resistance of that portion can be increased. As a result, it is possible to reduce eddy current loss that occurs when the rotating electrical machine is driven, and it is possible to improve the efficiency of the rotating electrical machine.

  FIG. 5 shows an explanation conceptually explaining the method for manufacturing the spirally wound core 34 of the third embodiment.

  For example, the spirally wound core 20 as shown in FIG. 8 created by the method of FIG. 7 is set on a table of a winding machine (not shown), for example. This winding machine has a structure having a winding nozzle that revolves around the spiral wound core 20 while feeding out the magnetic wire 36, and a winding nozzle around which the bed holding the spiral wound core 20 feeds the magnetic wire 36. Any structure such as a revolving structure can be used.

  At this time, it is preferable that the spiral wound core 20 presses only the portion of the tooth portion 16 with the block 38 or the like so that the magnetic wire 36 does not bite into the tooth portion 16 when the magnetic wire 36 is wound. Thereafter, a predetermined amount of the magnetic wire 36 is sequentially inserted into the gap S using a winding machine as described above. Note that the winding (insertion) density of the magnetic wire 36 can be adjusted as appropriate by adjusting the tension of the magnetic wire 36 fed out by the winding machine. Winding can be inserted.

  By the way, as shown in FIG. 6, cooling connection portions 40 a and 40 b can be formed at the start and end of the magnetic wire 36 inserted in the gap S of the spirally wound core 34. The cooling part to which the cooling connection parts 40a and 40b are connected is arbitrary as long as it is lower than the temperature of the spirally wound core 34 when the rotating electric machine is driven, and may be, for example, an outer housing of the rotating electric machine. Further, it may be a structure provided around, such as an arbitrarily provided heat sink. In addition, a refrigerant flow path of a device in which the rotating electrical machine is mounted, for example, when the rotating electrical machine is mounted in an automobile, a coolant path connected to a radiator or a flow path of a cooling device provided arbitrarily. There may be.

  Thus, by connecting the cooling connection portions 40a and 40b to the cooling portion, the heat generated in the spirally wound core 34 is efficiently radiated through the magnetic wire 36 filled in the gap S of the spirally wound core 34. can do. Therefore, by inserting the magnetic wire 36 into the gap S, the magnetic performance and rigidity of the spirally wound core 34 can be recovered to the same level as that of the conventional laminated core, and the spirally wound core 34 is cooled, that is, a rotating electrical machine. Can be cooled, which can contribute to improving the performance of the rotating electrical machine.

  FIG. 6 shows an example in which one magnetic wire 36 is wound around the gap S of the spirally wound core 34, but as described above, a plurality of magnetic wires 36 may be provided. In this case, it is desirable to provide a cooling connection portion at the end portion (at least one of the start end and the end end) of each magnetic wire 36, and the cooling efficiency can be improved as the number of cooling connection portions increases.

  As described in the above embodiments, even when a spirally wound core capable of reducing the material cost is adopted, a conventional laminated core can be obtained by filling (inserting) a magnetic body into a gap generated in the structure of the spirally wound core. Can restore the same level of magnetic performance and rigidity. In addition, flapping of the strip-shaped core material forming the wound layer is eliminated by eliminating the gap, and vibration of the rotating electrical machine and generation of abnormal noise can be prevented. Furthermore, by using a powder magnetic core or a magnetic wire as the magnetic material, an eddy current suppressing performance can be obtained. In particular, when a magnetic wire is used, the cooling performance of the core can be improved over that of the laminated core.

  In FIGS. 1B and 4 in the first and third embodiments, the magnetic material is also shown on the uppermost surface and the lowermost surface of the strip-shaped core material constituting the spirally wound core. Actually, the magnetic body cannot be held on the uppermost surface and the lowermost surface. Therefore, the magnetic body is held by adhering a dust core in the same manner as in the second embodiment with respect to the uppermost surface and the lowermost surface. In addition, if a presser plate or the like is arranged on the uppermost surface and the lowermost surface of the spirally wound core, it becomes possible to form a gap between the uppermost surface and the lowermost surface of the belt-like core material and the presser plate. , 3 can be filled with the magnetic material.

  Moreover, although embodiment mentioned above demonstrated the separate structure, you may comprise the spiral wound core which combined the structure of Embodiment 1-3 arbitrarily, and can acquire the same effect.

  Further, in the present embodiment, the stator core of the inner rotor type rotating electrical machine has been described as an example, but the present embodiment can also be applied to the rotor core, and similar effects can be obtained. Further, it can be similarly applied to an outer rotor type rotating electrical machine, and the same effect can be obtained.

3 is a cross-sectional view illustrating a configuration of a spirally wound core of the rotating electrical machine according to Embodiment 1. FIG. It is explanatory drawing explaining the production method of the spiral winding core of the rotary electric machine which concerns on Embodiment 1. FIG. 6 is a cross-sectional view illustrating a configuration of a spirally wound core of a rotating electrical machine according to Embodiment 2. FIG. It is sectional drawing explaining the structure of the spiral winding core of the rotary electric machine which concerns on Embodiment 3. FIG. It is explanatory drawing explaining the production method of the spiral winding core of the rotary electric machine which concerns on Embodiment 3. FIG. It is explanatory drawing explaining the magnetic fine wire which has a cooling connection part used for the spiral winding core of the rotary electric machine which concerns on Embodiment 3. FIG. It is explanatory drawing explaining the creation method of a spiral wound core. It is explanatory drawing explaining the strip | belt-shaped core material wound spirally. It is explanatory drawing explaining that a clearance gap is formed in the outer peripheral side of a spiral winding core by having wound spirally.

Explanation of symbols

  10 Slot part, 12 Strip core material, 14 Yoke part, 16 teeth part, 18 Unequal pressure roller, 20, 26, 30, 34 Spiral wound core, 22 Housing, 24 Magnetic powder, 28, 38 block, 32 Compaction Magnetic core, 36 magnetic wire, 40a, 40b Cooling connection, P gathering gap, S gap.

Claims (6)

In the spiral wound core of the rotating electrical machine formed by spirally winding and laminating the strip-shaped core material formed at equal intervals on one end side in the width direction, the slot portion,
A rotation characterized in that a magnetic material is filled in an axial gap of the spirally wound core accompanying thinning of the outer peripheral side with respect to the inner peripheral side of the spirally wound core generated by spirally winding the band-shaped core material. Electric spiral core. The core of claim 1,
The spirally wound core of a rotating electrical machine, wherein the magnetic material is a magnetic powder, and the magnetic powder is filled in a gap between the winding layers of a spirally wound belt-like core material. The core of claim 2,
A spiral wound core of a rotating electrical machine, wherein the magnetic powder is filled in each winding interlayer gap together with an adhesive. The core of claim 1,
The magnetic body is a dust core, and the dust core is attached to a collective gap formed as a result of closely contacting each winding interlayer gap formed on a spirally wound belt-like core material. Spiral wound core. The core of claim 1,
The spirally wound core of a rotating electrical machine, wherein the magnetic material is a magnetic wire, and the magnetic wire is filled in a space between each winding layer of a spirally wound belt-like core material. The core of claim 5,
A spiral wound core of a rotating electrical machine, wherein a cooling connection portion is provided at an end of the magnetic thin wire.

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