JP2006353054A - Manufacturing method of stator for axial gap type rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator for a rotary electric machine which reduces cost by reducing a die expense, and moreover improves the circumferential rigidity of stator teeth. <P>SOLUTION: Convex portions of a magnetic steel sheet band, having concave and convex portions at fixed intervals, are cut off so that the widths of the convex portions may change, then U-shaped magnetic steel sheets of a plurality of patterns are formed. The U-shaped magnetic steel sheets of thus obtained are laminated, in the order of the sheets of narrower widths to form a plurality of stator core blocks 16, then a plurality of the stator core blocks 16 are combined so that the blocks form concave and convex shapes in the peripheral direction and a stator core 17 is formed. The stator core 17 thus formed is fixed to a stator plate which rotatably supports the rotating shaft of a rotor. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a stator of an axial gap type rotating electrical machine in which a stator and a rotor are arranged to face each other along a rotation axis.

  A rotating electrical machine having a permanent magnet on a rotor is used in many automobiles or industrial machines for reasons such as low loss, high efficiency, and high output. In particular, the axial gap type rotating electrical machine in which the stator and the disk-shaped rotor are disposed so as to face each other along the rotation axis can be reduced in thickness in the direction of the rotation axis, and thus there are restrictions on the layout. More often used.

By the way, in the axial gap type rotating electric machine, the stator teeth are formed by stamping a directional electromagnetic steel sheet into a substantially I shape and laminating these. Further, the stator teeth are formed so that the width of the inner peripheral portion is narrow and the width of the outer peripheral portion is wide, and this is a trapezoidal shape when viewed from the upper surface (for example, Patent Document 1). The reason why the stator teeth are trapezoidal is to reduce the useless space between the stator teeth and increase the efficiency of the electric motor by arranging the stator teeth in a ring shape. Further, in order to improve the workability of winding the stator teeth, it has been conventionally performed that the back yoke portion can be detached from the stator teeth.
JP 2005-51929 A

  However, in order to form the stator teeth in a trapezoidal shape that increases in width from the inner periphery to the outer periphery in an axial gap type rotating electrical machine, multiple shapes of electrical steel sheets with different widths are manufactured using multiple dies. There was a problem that it was expensive. In addition, since the stator teeth and the stator back yoke are separate, the stator teeth are susceptible to stress applied in the circumferential direction when the rotating electrical machine is driven.

  The present invention has been made in view of such problems, and an object of the present invention is to reduce the cost of the mold and reduce the cost, and further improve the circumferential rigidity of the stator teeth during the rotation drive. Another object of the present invention is to provide a method of manufacturing a stator for an axial gap type rotating electrical machine that can be made to operate.

  In order to achieve the above object, a first invention is an axial including a rotor in which a plurality of permanent magnets are provided in a circumferential direction, and a stator that is disposed to face each other with a predetermined gap along a rotation axis of the rotor. In the method of manufacturing a stator in a gap type rotating electrical machine, a plurality of patterns of U-shaped electromagnetic steel sheets are formed by cutting the protrusions of the electromagnetic steel sheet strips having irregularities with a constant interval so that the width of the protrusions changes. The obtained U-shaped electromagnetic steel sheets are laminated in order from the narrowest one to form a plurality of laminated steel sheet blocks, and the plurality of laminated steel sheet blocks are combined so as to be uneven in the circumferential direction. The stator core thus formed is fixed to a stator plate that rotatably supports the rotating shaft of the rotor.

  Further, the second invention is an axial gap type rotating electrical machine including a rotor in which a plurality of permanent magnets are provided in a circumferential direction and a stator that is disposed to face each other with a predetermined gap along a rotation axis of the rotor. In the stator manufacturing method, a plurality of patterns of U-shaped electromagnetic steel sheets, and L-shaped electromagnetic steel sheets are obtained by cutting the convex portions of the electromagnetic steel sheet strips having irregularities at regular intervals so that the width of the convex portions changes. Forming an inverted L-shaped electrical steel sheet, and obtaining the obtained U-shaped electrical steel sheet, the L-shaped electrical steel sheet, and the inverted L-shaped electrical steel sheet in order of decreasing width. A plurality of laminated steel plate blocks are laminated to form a stator core by combining the plurality of laminated steel plate blocks so as to be uneven in the circumferential direction, and the formed stator core can be rotated about the rotating shaft of the rotor. Supporting stator Characterized by fixed rate.

  A third invention is an axial gap type rotating electrical machine including a rotor in which a plurality of permanent magnets are provided in a circumferential direction and a stator that is disposed to face each other with a predetermined gap along a rotation axis of the rotor. In the stator manufacturing method, a plurality of electromagnetic steel sheets are formed by cutting the electromagnetic steel sheet strips to change the width, and the obtained electromagnetic steel sheets are laminated in order from the smallest width to form a plurality of laminated steel sheet blocks. The stator core is formed by inserting a plurality of laminated steel plate blocks from the outer peripheral side into fitting portions provided at equal intervals in the circumferential direction of the stator back yoke formed by laminating electromagnetic steel plates. Is fixed to a stator plate that rotatably supports the rotating shaft of the rotor.

  The stator core is preferably fixed to the stator plate by caulking, and a protrusion formed on a back yoke portion of the stator core and a fitting portion formed on the stator plate are fitted and fixed. In addition, it is preferably fixed by an adhesive, and further, a U-shaped claw is inserted from the inner peripheral side and / or outer peripheral side of the stator into the concave portion of the stator core and the fitting hole of the stator plate and fixed. It is preferable.

  According to the first and second inventions, since the electromagnetic steel sheet strip is manufactured by one mold and processed by wire cutting or the like to form the stator teeth, the mold cost can be reduced and the cost can be reduced. In addition, since the roots of the stator teeth and the stator back yoke are integrally formed, it is possible to improve the circumferential rigidity of the stator teeth when the rotating electrical machine is driven.

  Further, according to the third invention, since the stator teeth are formed by processing the electromagnetic steel sheet strip by wire cutting or the like without using a mold, the mold cost can be reduced and the cost can be reduced. Further, the stator teeth are inserted from the outer peripheral side into the fitting portions provided at equal intervals in the circumferential direction of the stator back yoke, and the circumferential direction side surface of the stator teeth is supported by the stator back yoke. The rigidity of the circumferential direction of the stator teeth during driving can be improved.

  Further, the stator core is fixed to the stator plate by caulking, or the stator core is fixed to the stator plate by fitting a protrusion formed on the back yoke portion of the stator core and a fitting portion formed on the stator plate, Alternatively, since the stator core is fixed to the stator plate with an adhesive and the stator core is fixed to the stator plate with a U-shaped claw, the circumferential rigidity of the stator teeth can be further improved.

  Before describing the method of manufacturing a stator of the present invention, an axial gap type rotating electrical machine in which a stator formed by the method of the present invention is used will be described first. FIG. 1 is a schematic cross-sectional view showing an embodiment of an axial gap type rotating electrical machine. This axial gap type rotating electric machine includes a rotor 4 in which a plurality of permanent magnets 1 are provided on a disk-shaped holding member 2 at regular intervals in the circumferential direction, and the holding member is connected to a rotating shaft 3. A plurality of stator teeth 5 which are arranged to face each other along the central axis 4 and are laminated with electromagnetic steel plates are arranged at equal intervals in the circumferential direction, and the plurality of stator teeth 5 are fixed to the stator back yoke 6. The stator 8 is formed by winding a coil 7 around each stator tooth 5 and a motor case 10 that fixes the stator 8 and rotatably supports the rotating shaft 3 via a bearing 9.

  In the axial gap type rotating electric machine shown in FIG. 1, a pair of stators 8 are provided so as to face each other with the rotor 4 interposed therebetween, a cooling path 13 is provided in the motor case 10, and the stator teeth 5 and the coil 7 are lost. A coolant for absorbing and cooling the heat is circulated. Further, an encoder 14 for detecting the rotation amount and position of the rotor 4 is provided at the end of the rotating shaft 3, and electromagnetic waves are used between the adjacent permanent magnets 1 of the rotor 4 in order to use reluctance torque. A rotor core 15 made of a steel plate is provided.

  In the axial gap type rotating electrical machine shown in FIG. 1, when the coil 7 is excited by an inverter (not shown), a rotating magnetic field is formed in the circumferential direction of the stator 8, and a plurality of permanent magnets 1 having different polarities alternately are embedded in the circumferential direction. The disk-shaped rotor 4 is attracted and repelled by the rotating magnetic field generated by the stator 8 to generate magnet torque, and also generates reluctance torque due to the presence of the magnetic material constituting the rotor 4, which is used as power. The rotor 4 rotates at a synchronous speed with the rotating magnetic field.

  2 to 4 are schematic views showing a first embodiment of a method of manufacturing a stator for an axial gap type rotating electrical machine according to the present invention. FIG. 2 is a diagram for explaining a method of producing an electromagnetic steel plate (laminated plate) necessary for forming a stator core of a rotating electrical machine. As shown in FIG. 2, an electromagnetic steel plate having uneven portions with a constant interval by one mold. A band is manufactured, and the convex portions of the electromagnetic steel sheet band are cut into patterns 1 to N by wire cutting or the like, and one or two types of U-shaped electromagnetic steel sheets are created from each.

  Next, as shown in FIG. 3, the stator core block 16 in which the stator teeth (half) and the back yoke are integrated is formed by laminating the magnetic steel sheets prepared in FIG. To do. FIG. 4 shows a state when the stator core 17 is formed by combining the stator core block 16 of FIG. 3 so that the width of the inner peripheral portion is narrow and the width of the outer peripheral portion is widened.

  According to this stator manufacturing method, the electromagnetic steel sheet strip is manufactured by one mold and processed by wire cutting or the like to form the stator teeth, so that the mold cost can be reduced and the cost can be reduced. In addition, since the base of the stator teeth and the stator back yoke that are stressed is integrally formed, the rigidity of the stator teeth in the circumferential direction is improved.

  5 to 7 are schematic views showing a second embodiment of the stator manufacturing method of the present invention. FIG. 5 is a diagram for explaining a method of forming an electromagnetic steel plate (laminated plate) necessary for forming a stator core of a rotating electrical machine. An electromagnetic steel plate strip having uneven portions with a constant interval is manufactured by one mold, and FIG. As shown in (a), the steel sheet has two convex portions by wire cutting or the like so that the length of the concave portion sandwiched between the convex portions is a and the length of the concave portions at the left and right ends is a / 2. The strip is cut, and as shown in FIG. 5 (b), the projections of the electromagnetic steel sheet obtained by cutting are cut as in patterns 1 to N, and each of them is an inverted L-shaped electromagnetic steel sheet A. The U-shaped electrical steel sheet B and the L-shaped electrical steel sheet C are prepared.

  Next, as shown in FIG. 6, the electromagnetic steel plates A, B, and C created in FIG. 5 are laminated in order from the narrowest one to form the stator core block A, the stator core block B, and the stator core block C. The stator core block A and the stator core block C are combined to form a stator core block having the same shape as the stator core block B. As shown in FIG. 7, the stator core block has a narrow inner peripheral portion and a wider outer peripheral portion. In this way, the stator core 18 is formed.

  According to this stator manufacturing method, the electromagnetic steel sheet strip is manufactured by one mold and processed by wire cutting or the like to form the stator teeth, so that the mold cost can be reduced and the cost can be reduced. In addition, since the base of the stator teeth and the stator back yoke that are stressed is integrally formed, the rigidity of the stator teeth in the circumferential direction is improved.

8 to 11 are schematic views showing a third embodiment of the stator manufacturing method of the present invention. FIG. 8 is a diagram for explaining a method for producing an electromagnetic steel plate (laminated plate) necessary for forming a stator core of a rotating electrical machine. As shown in FIG. Cut (x) to (x + a _n ) to produce (n + 1) electromagnetic steel sheets having different widths.

  Next, as shown in FIG. 9, the stator teeth 20 are formed by laminating the (n + 1) electromagnetic steel sheets having different widths created in FIG. 8 in order from the narrowest width, and as shown in FIG. The stator teeth 20 formed by laminating electromagnetic steel plates are inserted from the outer peripheral side into the fitting portions 22 provided at equal intervals in the circumferential direction of the stator back yoke 21 formed by laminating electromagnetic steel plates to form a stator core. . FIG. 11 is a partially enlarged perspective view showing a state after the stator teeth 20 are inserted into the fitting portion 22 of the stator back yoke 21.

  According to this stator manufacturing method, since the stator teeth are formed by processing the electromagnetic steel sheet strip by wire cutting or the like without using a mold, the mold cost can be reduced and the cost can be reduced. Further, since the stator teeth are inserted into the fitting portions of the stator back yoke and the circumferential side surfaces of the stator teeth are supported by the stator back yoke, the rigidity of the stator teeth in the circumferential direction is improved.

  Next, a method of fixing the stator core formed as described above to a stator plate that is a motor case that rotatably supports the rotating shaft of the rotor will be described. 12, the stator core block 26 created in FIG. 4 is fixed to the stator plate 27 by caulking 28 at the bonded portion of the stator core block 26. In FIG. 13, the stator core block 26 created in FIG. 14 is fixed by caulking 28 at the bonded portion of the stator core block 26, and in FIG. 14, the stator core created in FIG. 11 is fixed to the stator plate 27 by caulking 28 at the contact portion of the stator teeth 20 and the stator back yoke 21. is doing.

  According to this, since the circumferential force acting on the stator teeth during operation of the rotating electrical machine can be supported with high rigidity by the caulking 28 between the stator core and the stator plate 27, the circumferential force of the stator teeth can be increased. The support rigidity can be further increased.

  In FIG. 15, the stator core block 26 created in FIG. 4 is fixed to the stator plate 27 by fitting the protrusion 29 formed on the back yoke portion of the stator core block 26 and the fitting portion formed on the stator plate 27. In FIG. 16, the stator core block 26 created in FIG. 7 is fitted to the stator plate 27, and the protrusion 29 formed on the back yoke portion of the stator core block 26 is fitted to the fitting portion provided on the stator plate 27. In FIG. 17, the stator core created in FIG. 11 is fixed to the stator plate 27, and the protrusion 29 formed on the stator back yoke 21 is fitted to the fitting portion provided on the stator plate 27. ing.

  According to this method, the circumferential force acting on the stator teeth during the operation of the rotating electrical machine can be supported with high rigidity by the fitting between the projections 5a of the stator core and the fitting portions provided on the stator plate 27. Therefore, the support rigidity in the circumferential direction of the stator teeth can be further increased.

  18 shows a method of fixing the stator core block 26 created in FIG. 4 to the stator plate 27 with an adhesive 30. FIG. 19 shows the method of fixing the stator core block 26 created in FIG. FIG. 20 shows a method of fixing the stator core created in FIG. 11 to the stator plate 27 with an adhesive 30. The method of fixing by caulking as shown in FIGS. 12, 13 and 14, or the protrusions formed on the stator core shown in FIGS. 15, 16 and 17 and the fitting portions formed on the stator plate are fitted together. By using the method of fixing together with the method of fixing with the adhesive shown in FIGS. 18, 19, and 20, the circumferential rigidity of the stator teeth can be further increased.

  In FIG. 21, the stator core block 26 formed in FIG. 4 is formed by using a U-shaped claw 31 from the inner peripheral side and the outer peripheral side of the stator, with one claw being the recess of the stator core block 26 and the other claw being the stator plate. It is fixed to the stator plate 27 by being inserted into a fitting hole formed in the member 27. 22 is a perspective view when the stator core block 26 is fixed to the stator plate 27 using a U-shaped claw 31. FIG. 23 is a sectional view taken along the line AB of FIG. It is.

  Here, the U-shaped claw 31 is inserted from the inner peripheral side and the outer peripheral side of the stator and the stator core block 26 is fixed to the stator plate 27. However, the U-shaped only from the inner peripheral side or the outer peripheral side of the stator. It is also possible to fix the stator core block 26 to the stator plate 27 by inserting mold claws 31. Although not shown, the starter core formed in FIGS. 7 and 11 can also be fixed to the stator plate 27 using the U-shaped claw 31.

  According to this method, since the circumferential force acting on the stator teeth when the rotating electrical machine is driven can be supported with high rigidity by the U-shaped claws 31, the circumferential support rigidity of the stator teeth can be further increased. Can be increased.

  In addition, it fixes to the method fixed by the caulking shown in FIG.12, FIG.13 and FIG.14 in the method fixed using a nail | claw, and the protrusion part and stator plate which were formed in FIG.15, FIG.16 and FIG. It is also possible to use a method of fitting and fixing with the fitting portion, and a method of fixing with an adhesive shown in FIGS. 18, 19 and 20 in combination.

It is a schematic cross section which shows one Embodiment of an axial gap type rotary electric machine. It is a schematic diagram which shows 1st Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 1st Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 1st Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 2nd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 2nd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 2nd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 3rd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 3rd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 3rd Example of the manufacturing method of the stator of this invention. It is a schematic diagram which shows 3rd Example of the manufacturing method of the stator of this invention. FIG. 5 is a view showing a method of fixing the stator core block and the stator plate created in FIG. 4 by caulking. It is a figure which shows the method of fixing the stator core block and stator plate which were produced in FIG. 7 by caulking. It is a figure which shows the method of fixing the stator core and stator plate which were produced in FIG. 11 by caulking. FIG. 5 is a diagram showing a method of fixing the stator core block and the stator plate created in FIG. 4 by fitting protrusions formed on the back yoke portion of the stator core to fitting portions formed on the stator plate. FIG. 8 is a diagram illustrating a method of fixing the stator core block and the stator plate created in FIG. 7 by fitting protrusions formed on the back yoke portion of the stator core to fitting portions formed on the stator plate. FIG. 12 is a diagram illustrating a method of fixing the stator core and the stator plate created in FIG. 11 by fitting a protrusion formed on the stator back yoke to a fitting portion formed on the stator plate. It is a figure which shows the method of fixing the stator core block and stator plate which were produced in FIG. 4 with the adhesive agent. It is a figure which shows the method of fixing the stator core block and stator plate which were produced in FIG. 7 with the adhesive agent. It is a figure which shows the method of fixing the stator core and stator plate which were produced in FIG. 11 with an adhesive agent. It is a figure which shows the method of fixing the stator core block and stator plate which were produced in FIG. 4 or FIG. 7 using a U-shaped nail | claw. It is a perspective view when a stator core block and a stator plate are fixed using a U-shaped claw. It is sectional drawing along the AA line of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Permanent magnet 2 Holding member 3 Rotating shaft 4 Rotor 5, 20 Stator teeth 6, 21 Stator back yoke 7 Coil 8 Stator 9 Bearing 10 Motor case 13 Cooling path 14 Encoder 15 Rotor core 17, 18 Stator core 22 Fitting part 16, 26 Stator core Block 27 Stator plate 28 Caulking 29 Protrusion 30 Adhesive 31 Claw

Claims (7)

In a stator manufacturing method in an axial gap type rotating electrical machine including a rotor in which a plurality of permanent magnets are provided in a circumferential direction, and a stator that is disposed to face the rotor with a predetermined gap along a rotation axis of the rotor,
The convex part of the electromagnetic steel strip having irregularities at regular intervals is cut so that the width of the convex part is changed to form a plurality of patterns of U-shaped electrical steel sheet, and the obtained U-shaped electrical steel sheet A plurality of laminated steel plate blocks are laminated in order from the narrowest one, and a plurality of laminated steel plate blocks are combined so as to be uneven in the circumferential direction to form a stator core. A stator manufacturing method for an axial gap type rotating electrical machine, wherein the rotating shaft is fixed to a stator plate that rotatably supports the rotating shaft. In a stator manufacturing method in an axial gap type rotating electrical machine including a rotor in which a plurality of permanent magnets are provided in a circumferential direction, and a stator that is disposed to face the rotor with a predetermined gap along a rotation axis of the rotor,
A plurality of patterns of U-shaped electromagnetic steel sheets, L-shaped electromagnetic steel sheets, and inverted L-shaped magnetic steel sheets are formed by cutting the convex portions of the electromagnetic steel sheet strips having irregularities at regular intervals so that the width of the convex portions changes. Forming an electromagnetic steel sheet, and laminating an obtained U-shaped electromagnetic steel sheet, an L-shaped electromagnetic steel sheet, and an inverted L-shaped electromagnetic steel sheet in order from the smallest width to a plurality of A laminated steel plate block is formed, a plurality of laminated steel plate blocks are combined so as to be uneven in the circumferential direction, a stator core is formed, and the formed stator core is fixed to a stator plate that rotatably supports the rotating shaft of the rotor. A method for manufacturing a stator for an axial gap type rotating electrical machine. In a stator manufacturing method in an axial gap type rotating electrical machine including a rotor in which a plurality of permanent magnets are provided in a circumferential direction, and a stator that is disposed to face the rotor with a predetermined gap along a rotation axis of the rotor,
A plurality of magnetic steel sheets are formed by cutting the magnetic steel sheet strips to change the width, and the obtained electromagnetic steel sheets are laminated in order from the smallest width to form a plurality of laminated steel sheet blocks. A stator core is formed by inserting a steel plate block from the outer peripheral side into a fitting portion provided at equal intervals in the circumferential direction of a stator back yoke formed by laminating electromagnetic steel plates, and the formed stator core is rotated by the rotor. A method of manufacturing a stator for an axial gap type rotating electrical machine, wherein the shaft is fixed to a stator plate that rotatably supports the shaft.   The method for manufacturing a stator for an axial gap rotating electrical machine according to any one of claims 1 to 3, wherein the stator core is fixed to the stator plate by caulking.   4. The stator core is fixed to a stator plate by fitting a protrusion formed on a back yoke portion of the stator core and a fitting portion formed on the stator plate. A stator manufacturing method for an axial gap type rotating electrical machine according to claim 1.   The stator manufacturing method for an axial gap type rotating electrical machine according to any one of claims 1 to 5, wherein the stator core is fixed to a stator plate with an adhesive.   The stator core is fixed to the stator plate, and U-shaped claws are inserted into the recesses of the stator core and the fitting holes of the stator plate from the inner peripheral side and / or outer peripheral side of the stator. A method of manufacturing a stator for an axial gap type rotating electrical machine according to any one of claims 6 to 10.

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