JP2007135356A - Manufacturing method of stator, and the stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator manufacturing method that enables the diameter in the circumferential direction on a surface that faces a rotor to be fixed, in a core comprising a plurality of divided cores that are to be arrayed annularly. <P>SOLUTION: In a divided-core forming process, the divided cores 5 are formed, in such a way that projections 5c have a portion protruding inside the radial direction from a circle C1, which has a diameter that is equal to the length of the reference dimension Ds of the inside diameter of a stator core 4, when the divided cores 5 are arrayed in the circumferential direction. In a forming process, a plurality of the divided cores 5 are arrayed in the circumferential directions so that teeth 5b become radial and are arranged annularly, to form the stator core 4. In a reforming process, the projections 5c are pressed by a reforming tool to the base end side of the teeth 5b, and the top end surfaces 5d of the teeth 5b are shaped along the circle C1. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a stator provided in a rotating electrical machine.

  Conventionally, a rotating electrical machine includes a rotor and a stator that faces the rotor in a radial direction. The stator includes, for example, a core having a cylindrical annular portion and teeth extending from the annular portion along the radial direction. Protruding portions that are formed to protrude toward both sides in the circumferential direction are provided at the tip of the teeth, and the tip surface of the teeth including the protruding portions faces the rotor in the radial direction. As such a core, a structure in which divided cores having a shape divided for each tooth are arranged in a ring shape has been proposed. When manufacturing a stator having this core, if the winding is wound around each tooth before shaping the plurality of divided cores into an annular shape, the winding is wound without the adjacent teeth interfering with each other. Therefore, the space factor of the winding can be improved.

  By the way, a core formed by shaping a plurality of split cores into an annular shape has a dimensional error for each split core, so the inner diameter and outer diameter of the core are smaller than those of an integrated core that is not split for each tooth. It is difficult to make the roundness of the diameter highly accurate. In the rotating electrical machine, the cogging torque in the rotating electrical machine is increased if the roundness of the facing surface (the inner peripheral surface or the outer peripheral surface of the core) facing the rotor in the core is not maintained with high accuracy. There is a risk of increased vibration and noise. For example, if vibration and noise are increased by a motor used in an electric power steering device mounted on an automobile, vibration is transmitted to the driver through the steering wheel, or noise in the vehicle interior is increased. There are times when it falls.

Therefore, in Patent Document 1, for example, the tip of the teeth in the assembled core is relatively pressed against the outer peripheral surface of the mandrel having an outer diameter serving as a reference dimension, so that the inner diameter of the core is made to be the processing accuracy of the mandrel. The roundness is improved accordingly. The “reference dimension” means a dimension of the core that does not include an error.
Japanese Patent Laid-Open No. 2002-199666

  By the way, for example, in an inner rotor type rotating electrical machine, the split core before assembly is usually formed with an arc shape at the tip of the tooth so that the inner diameter of the core formed by assembling the split core is equal to the reference dimension. It is formed in accordance with a circle having a diameter with a length equal to the reference dimension. As shown in FIGS. 7A and 7B, in the assembled core 51, due to the dimensional error of each divided core 52, the protruding portion 52c has a diameter having a length equal to the reference dimension D2. It protrudes radially inward from the circle C2 it has, or is arranged at a position radially outward from the circle C2. In FIGS. 7A and 7B, of the protrusions 52c, a protrusion 52c having a portion protruding radially inward from the circle C2 is defined as a first protrusion 53a, which is more than the circle C2. The protruding portion 52c arranged at a position on the outer side in the radial direction is a second protruding portion 53b. When the method described in Patent Document 1 is used for the core 51 in this state, as shown in FIGS. 7 (c) and 7 (d), the first protruding portion 53a has a pressing force applied from the mandrel. Is corrected to a shape corresponding to the mandrel. However, since the mandrel is not brought into contact with the second projecting portion 53b, it is difficult to form the second projecting portion 53b according to the mandrel. Therefore, in the method described in Patent Document 1, there is a case where the tip of the tooth 52b cannot be partially formed into a shape along a circle C2 having a diameter equal to the reference dimension D2. As described above, the method of Patent Document 1 has a problem that the inner diameter of the core, that is, the diameter of the facing surface of the core may not be constant in the circumferential direction. The same applies to the case of correcting the outer diameter of the stator core provided in the outer rotor type rotating electrical machine.

  The present invention has been made in view of such circumstances, and the object thereof is to make the diameter of the facing surface facing the rotor in a core formed by annularly arranging a plurality of divided cores constant in the circumferential direction. It is an object to provide a method for manufacturing a stator and a stator.

  In order to solve the above-mentioned problem, the invention described in claim 1 is characterized in that a plurality of split cores each including a tooth and a protruding portion formed in a circumferential direction from the tip of the tooth are arranged so that the teeth are radial. A stator manufacturing method comprising a core arranged in a circumferential direction and a facing surface that faces the rotor in a radial direction is configured by a tip surface of the tooth including the protruding portion, wherein the divided core is arranged in the circumferential direction. The divided cores are arranged so that the protruding portion has a portion protruding to the side where the rotor is arranged rather than a circle having a diameter equal to a reference dimension of the diameter of the facing surface when arranged in A divided core forming step of forming a plurality of the divided cores in a circumferential direction so that the teeth are radially formed, a shaping step of shaping the core into an annular shape, and the projecting portion by the straightening tool Tee Pressed toward the proximal end of the scan, and the gist thereof by comprising a correction step of a shape along the opposing surface on the circle.

  According to the same configuration, the protruding portion of the split core formed in the split core forming step protrudes to the side where the rotor is disposed from the reference circle having a diameter equal to the reference dimension of the diameter of the opposing surface. Has a site. Therefore, all the protrusions in the core teeth shaped in the shaping step have portions that protrude toward the side where the rotor is arranged, rather than the reference circle. Therefore, in the straightening process, since all the protruding portions can be pressed toward the base end side of the teeth by the correction tool, it is possible to prevent a protruding portion that is not partially corrected as in the past from occurring. it can. As a result, all protrusions can be pressed to the base end side of the teeth with a correction tool, and the tip end surface of the teeth can be shaped along the reference circle. It is possible to make the direction constant.

  In the present invention, the “opposing surface” means a cylindrical surface (including a portion partially interrupted in the circumferential direction) constituted by the tip surfaces of a plurality of teeth facing the rotor in the radial direction. To do. Therefore, in the stator provided in the inner rotor type rotating electrical machine, the “opposing surface” is the inner peripheral surface of the core, and the “diameter of the opposing surface” is the inner diameter of the core. On the other hand, in the stator provided in the outer rotor type rotating electrical machine, the “opposing surface” is the outer peripheral surface of the core, and the “diameter of the opposing surface” is the outer diameter of the core.

  According to a second aspect of the present invention, in the stator manufacturing method according to the first aspect, in the shaping step, the plurality of divided cores are shaped such that tips of the teeth face radially inward, and the correction is performed. In the step, the straightening tool having an outer diameter equal to the reference dimension is inserted inside the core in the radial direction, the core and the straightening tool are rotated relative to each other in the circumferential direction, and the protrusion is projected by the straightening tool. The gist is to press the portion radially inward.

  According to this configuration, a protrusion having a portion protruding to the side where the rotor is disposed from the reference circle, that is, a protrusion having a portion protruding radially inward from the reference circle, has a length equal to the reference dimension. By pressing outward in the radial direction with a correction tool having an outer diameter, the inner diameter of the core of the stator provided in the inner rotor type rotating electrical machine can be made equal to the reference dimension. Further, in the straightening process, the core and the straightening tool are relatively rotated, so that the inner diameter of the core can be made constant in the circumferential direction with higher accuracy. As a result, the roundness of the core inner diameter can be further improved.

  According to a third aspect of the present invention, in the stator manufacturing method according to the first aspect, in the shaping step, the plurality of divided cores are shaped so that tips of the teeth face radially outward, and the correction is performed. In the step, the core is inserted into the straightening tool having an inner diameter equal to the reference dimension, the core and the straightening tool are rotated relative to each other in the circumferential direction, and the protrusion is radially formed by the straightening tool. The gist is to press inward.

  According to this configuration, a protrusion having a portion protruding to the side where the rotor is arranged from the reference circle, that is, a protrusion having a portion protruding radially outward from the reference circle, has a length equal to the reference dimension. By pressing inward in the radial direction with a straightening tool having an inner diameter, the outer diameter of the stator core provided in the outer rotor type rotating electrical machine can be made equal to the reference dimension. In the straightening process, the core and the straightening tool are relatively rotated, so that the outer diameter of the core can be made constant in the circumferential direction with higher accuracy. As a result, the roundness of the core outer diameter can be further improved.

  According to a fourth aspect of the present invention, in the stator manufacturing method according to the second or third aspect, in the straightening step, the straightening tool moves relative to the core along the axial direction of the core. The gist is to be done.

  According to this configuration, since the correction tool is moved relative to the core along the axial direction of the core, the inner diameter of the core can be made constant in the circumferential direction at any part of the core in the axial direction. it can.

  According to a fifth aspect of the present invention, in the stator manufacturing method according to any one of the second to fourth aspects, the straightening tool has a cylindrical shape extending along the axial direction of the core. A plurality of rollers arranged at intervals, and the plurality of rollers are rotatably held with the central axis thereof as a rotation axis. The gist is to press toward the base end side of the teeth.

  According to this configuration, since the roller can rotate about the central axis of the roller as a rotation axis, the sliding resistance between the tip surface of the tooth and the correction tool is reduced. Accordingly, the core and the correction tool are relatively rotated in the circumferential direction while the core and the correction tool are relatively moved in the axial direction, so that the relative movement along the axial direction of the correction tool with respect to the core is easy. It becomes.

The invention according to claim 6 is the gist of the stator manufacturing method according to claim 5, wherein the axial length of the roller is shorter than the axial length of the core.
According to this configuration, the roller has a length in the axial direction that is shorter than the length in the axial direction of the core, so that the length of the roller in the axial direction is greater than or equal to the length of the core in the axial direction. The contact area with is reduced. Therefore, compared with the case where the length of the roller in the axial direction is equal to or longer than the length of the core in the axial direction, the rotational torque when the core and the correction tool are rotated relative to each other can be reduced. Relative rotation can be performed more easily.

  A seventh aspect of the present invention is the stator manufacturing method according to the fifth or sixth aspect, wherein the core formed in the shaping step has a gap between the projecting portions adjacent in the circumferential direction. The gist of the invention is that the orthodontic tool includes a number of rollers that do not match the divisor of the number of teeth provided in the core.

According to the configuration, the roller is prevented from falling between the protrusions adjacent in the circumferential direction, and only a part of the protrusions is prevented from being biased and deformed.
According to an eighth aspect of the present invention, a plurality of split cores each including a tooth and a protruding portion that protrudes in the circumferential direction from the tip of the tooth are arranged in the circumferential direction so that the teeth are radial. The stator includes a protruding portion, and a front end surface of the teeth including the protruding portion forms a facing surface that faces the rotor in the radial direction, and the protruding portion has a length equal to a reference dimension of the facing surface. The gist of the invention is that it has a portion projecting to the side where the rotor is arranged from a reference circle having a diameter.

  According to this configuration, the protruding portion has a portion protruding from the reference circle to the side where the rotor is disposed. Therefore, all the projecting portions can be pressed toward the base end side of the tooth, and the tip end surface of the tooth can be shaped along the reference circle. Therefore, it becomes possible to make the diameter of the opposing surface comprised by the front-end | tip surface of teeth containing a protrusion part constant in the circumferential direction.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a stator and a stator which can make constant the diameter of the opposing surface which opposes the rotor in the core formed by arranging several division | segmentation cores cyclically | annularly can be provided. .

DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, an embodiment of the invention will be described with reference to the drawings.
FIG. 1 shows a brushless motor of this embodiment. As shown in FIG. 1, a substantially cylindrical stator 2 is press-fitted and fixed to the inner peripheral surface of a bottomed cylindrical case 1 constituting a brushless motor. A rotor 3 (shown by a one-dot chain line in FIG. 1) is disposed inside the stator 2. The rotor 3 includes a plurality of magnets (not shown) arranged in parallel in the circumferential direction, and is disposed inside the stator 2 so that the magnets face the stator 2.

  A stator core 4 as a core constituting the stator 2 is formed by arranging twelve divided cores 5 having a substantially T-shape when viewed in the axial direction in the circumferential direction, and press-fitted into the inner peripheral surface of the case 1 It is fixed.

  As shown in FIGS. 1 and 2A, each divided core 5 (only one is shown in FIG. 2A) includes a divided annular portion 5a in which the shape of the stator core 4 viewed from the axial direction is an arc shape. The teeth 5b extending from the center in the circumferential direction of the divided annular portion 5a as viewed from the axial direction of the stator core 4 so as to be substantially perpendicular to the divided annular portion 5a are integrally formed. Moreover, the protrusion part 5c protruded and formed in the circumferential direction both sides is integrally provided in the front-end | tip of the teeth 5b. Each divided core 5 is formed by alternately laminating two kinds of laminated members, a first laminated member 11 having a substantially T-shape and a second laminated member 12 having a symmetrical shape with the first laminated member 11. Is formed.

  As shown in FIG. 2B, the plate-like first laminated member 11 includes an arc-shaped laminated divided annular portion 11a that is laminated to form a divided annular portion 5a, and substantially perpendicular to the laminated divided annular portion 11a. A substantially rectangular first laminated tooth portion 11b extending so as to form a substantially rectangular shape, and a substantially triangular laminated protruding portion 11c protruding from the front end portion of the first laminated tooth portion 11b to both sides in the circumferential direction are integrally formed. .

  At one end in the circumferential direction of the laminated divided annular portion 11a (the left end portion in FIG. 2B) is formed an arc convex portion 11d projecting in an arc shape in the circumferential direction, and in the circumferential direction At the other end (the right end in FIG. 2B), an arc recess 11e is formed that is recessed in a substantially arc shape in the circumferential direction. And in the adjacent 1st laminated member 11, the circular arc convex part 11d of the other 1st laminated member 11 can be inserted from the radial direction outer side into the circular arc recessed part 11e of one 1st laminated member 11. FIG. Further, in the laminated divided annular portion 11a, a circumferential contact surface that contacts the radially inner portion of the portion where the arc convex portion 11d and the arc concave portion 11e are provided at the end position of rotation of the adjacent divided core 5 11f is formed. The circumferential contact surface 11f has a planar shape along a straight line extending in the radial direction of a cylindrical annular portion 4a (see FIG. 1) configured by assembling the divided annular portions 5a.

  In the 1st laminated member 11 comprised as mentioned above, the circular arc convex part 11d fits into the circular arc recessed part 11e of the 1st laminated member 11 which adjoins, and between the 1st laminated members 11 mutually by the circular arc convex part 11d and the circular arc recessed part 11e. The rotation is guided. Then, the circumferential contact surfaces 11 f of the adjacent first laminated members 11 are in contact with each other at the end position of the rotation of the split core 5.

  As shown in FIG. 2C, the second laminated member 12 is line symmetric with the first laminated member 11. The plate-like second laminated member 12 includes an arc-shaped laminated divided annular portion 12a that is laminated to form the divided annular portion 5a, and a substantially rectangular second extending so as to be substantially perpendicular to the laminated divided annular portion 12a. The two laminated teeth portion 12b and the substantially triangular laminated protrusion portion 12c protruding from the front end portion of the second laminated teeth portion 12b to both sides in the circumferential direction are integrally formed.

  At the other end in the circumferential direction of the laminated divided annular portion 12a (the end on the right side in FIG. 2 (c)), an arc convex portion 12d projecting in an arc shape in the circumferential direction is formed, and the circumferential direction At one end (the left end in FIG. 2C), an arc recess 12e is formed that is recessed in a substantially arc shape in the circumferential direction. And in the adjacent 2nd lamination | stacking member 12, the circular arc convex part 12d of the other 2nd lamination | stacking member 12 can be inserted from the radial direction outer side into the circular arc recessed part 12e of the one 2nd lamination | stacking member 12. FIG. Further, in the laminated divided annular portion 12a, a circumferential contact surface that abuts at the end position of the rotation of the adjacent divided core 5 on a portion radially inward of a portion where the arc convex portion 12d and the arc concave portion 12e are provided. 12f is formed. The circumferential contact surface 12f has a planar shape along a straight line extending in the radial direction of a cylindrical annular portion 4a (see FIG. 1) configured by assembling the divided annular portions 5a.

  In the second laminated member 12 configured as described above, the arc convex portion 12d fits into the arc concave portion 12e of the adjacent second laminated members 12, and the second laminated members 12 are connected by the arc convex portion 12d and the arc concave portion 12e. Is guided. Then, the circumferential contact surfaces 12 f of the adjacent second laminated members 12 are in contact with each other at the end position of the rotation of the split core 5.

  As shown in FIG. 2A, each of the divided cores 5 is formed by caulking the first laminated member 11 and the second laminated member 12 alternately laminated in the plate thickness direction. And the division | segmentation cyclic | annular part 5a is formed by the laminated | stacked division | segmentation cyclic | annular division | annular parts 11a and 12a, and the teeth 5b are formed by the laminated | stacked 1st and 2nd lamination | stacking teeth parts 11b and 12b, and also the lamination | stacking laminated | stacked A protrusion 5c is formed by the protrusions 11c and 12c. Note that the tip surface 5d of the tooth 5b including the protruding portion 5c has an arc shape when viewed from the stacking direction of the first and second stacked members 11 and 12.

  As shown in FIG. 1, in the stator core 4, the twelve divided cores 5 are arranged in the circumferential direction so that the tips of the teeth 5b are directed radially inward and the teeth 5b are radial. A cylindrical annular portion 4a is formed by the divided annular portions 5a arranged in the circumferential direction. Twelve slots 13 are formed by the teeth 5b adjacent in the circumferential direction, and a gap is provided between the protrusions 5c adjacent in the circumferential direction. An insulator 14 that covers portions other than the outer peripheral surface and the inner peripheral surface of the stator core 4 is attached to the stator core 4 from both sides in the axial direction of the stator core 4. A winding 15 is wound around each tooth 5 b so as to pass through the slot 13 from above the insulator 14. The winding 15 is supplied with power from a power supply device (not shown).

Next, a core straightening device used when manufacturing the stator core 4 will be described.
3 and 4 show the core straightening device 21 of the present embodiment. As shown in FIGS. 3 and 4, the core straightening device 21 includes a turntable 22, a straightening tool 23, a turntable drive device 24 that drives the turntable 22, and a straightening tool drive device 25 that drives the straightening tool 23. And a control device 26 for controlling the core straightening device 21.

  The turntable 22 has a cylindrical shape, and the turntable 22 is formed with a fixed recess 22a having an opening on the right end face in FIG. The fixed recess 22 a has a circular shape when viewed from the axial direction, and has an inner diameter that is substantially equal to the outer diameter of the case 1. The bottom surface of the fixed recess 22 a has a shape corresponding to the bottom of the case 1. The turntable 22 is supported so as to be rotatable in the circumferential direction by a support mechanism (not shown).

  The correction tool 23 includes a columnar slide shaft 31, a cylindrical roller support portion 32 disposed on the outer periphery of the slide shaft 31, and eleven circles rotatably supported by the roller support portion 32. A columnar roller 33 is provided.

  The slide shaft 31 has an outer diameter smaller than the inner diameter of the stator core 4. Then, the slide shaft 31 is arranged such that the left end face in FIG. 3 and the bottom surface of the fixed recess 22a face each other, the rotation axis of the rotary table 22, that is, the center axis of the fixed recess 22a, and the slide shaft 31. Are arranged so that their central axes coincide with each other. The slide shaft 31 is supported by a support mechanism (not shown) so as to be slidable along the axial direction.

  The roller support portion 32 has an inner diameter equal to the outer diameter of the slide shaft 31 and an outer diameter smaller than the inner diameter of the stator core 4. The roller support portion 32 is fixed so as to be able to move integrally with the slide shaft 31 such that the end surface on the rotary base 22 side is disposed in the same plane as the end surface of the slide shaft 31 on the rotary base 22 side. Has been. In the roller support portion 32, eleven roller support recesses 32 a are formed at positions closer to the turntable 22 than the central portion in the axial direction of the roller support portion 32. The eleven roller support portions 32 extend along the axial direction, and are formed at equal angular intervals in the circumferential direction. Each roller support recess 32a has an arc shape in which the length in the axial direction is shorter than the length in the axial direction of the stator core 4 and the center angle is larger than 180 ° when viewed from the axial direction. The eleven rollers 33 are accommodated in the roller support recesses 32a.

  Each roller 33 has a radius substantially equal to the radius of curvature of the inner peripheral surface of the roller support recess 32a when viewed from the axial direction, and the length in the axial direction is the length of the roller support portion 32 in the axial direction. Are equally formed. When the roller 33 is housed in the roller support recess 32a, the center axis of the roller 33 and the center axis of the slide shaft 31 are parallel to each other, and the roller support recess 32a rotates around the center axis as the rotation axis. It is held rotatably in the direction. The roller support recess 32a has an arc shape whose central angle is larger than 180 ° when viewed from the axial direction. Therefore, the roller 33 accommodated in the roller support recess 32a is a roller support recess. Omission from 32a is prevented. Further, the outer diameter D1 of the correction tool 23 including the roller 33 is formed to be equal to the reference dimension Ds of the inner diameter of the stator core 4 (see FIG. 6B). Incidentally, the “reference dimension of the inner diameter of the stator core” means the dimension of the inner diameter of the stator core 4 in the completed stator 2 without any dimensional error.

  The turntable driving device 24 includes a motor and the like, and rotates the turntable 22 in the circumferential direction. The correction tool driving device 25 includes a motor or the like, and moves the correction tool 23 in the left-right direction in FIG. 4 by sliding the slide shaft 31 along the axial direction of the slide shaft 31. Let The driving of the motors and the like constituting the turntable driving device 24 and the correction tool driving device 25 is controlled by the control device 26.

Next, a method for manufacturing the stator 2 using the core straightening device 21 will be described.
First, a divided core forming step is performed in which the first laminated member 11 and the second laminated member 12 are punched and formed, and the divided core 5 is formed by laminating the first laminated member 11 and the second laminated member 12. In the split core forming step, first, the first laminated member 11 and the second laminated member 12 are formed by punching a metal plate with a press (not shown). At this time, as shown in FIG. 5A, the first laminated member 11 has a tip end surface 11 g of the first laminated tooth portion 11 b including the laminated protruding portion 11 c, as viewed from the thickness direction, of the inner diameter of the stator core 4. Punching is performed so as to form an arc shape having a radius of curvature R1 smaller than the value obtained by dividing the reference dimension Ds by 2 (the radius of the inner diameter). Similarly, as shown in FIG. 5 (b), the second laminated member 12 has a tip end surface 12 g of the second laminated tooth portion 12 b including the laminated protruding portion 12 c that has an inner diameter of the stator core 4 as viewed from the plate thickness direction. Punching is performed so as to form an arc shape having a radius of curvature R2 smaller than the value obtained by dividing the reference dimension Ds by 2 (the radius of the inner diameter). In the present embodiment, the radius of curvature R1 of the tip surface 11g of the first laminated tooth portion 11b and the radius of curvature R2 of the tip surface 12g of the second laminated tooth portion 12b are the same value.

  Furthermore, the first laminated member 11 has a tip end surface 11g of the first laminated tooth portion 11b when twelve first laminated members 11 are arranged in the circumferential direction so that the laminated divided annular portion 11a has an annular shape. Is punched so as to be disposed on a circle C1 (shown by a broken line in FIG. 5A) having a diameter the same as the reference dimension Ds of the inner diameter of the stator core 4. Similarly, the second laminated member 12 has a tip end surface of the second laminated tooth portion 12b when twelve pieces of the second laminated member 12 are arranged in the circumferential direction so that the laminated divided annular portion 12a has an annular shape. The center part in the circumferential direction at 12 g is punched out so as to be arranged on the circle C1.

  Then, as shown in FIG. 5A, when the 12 first laminated members 11 punched and formed as described above are arranged in the circumferential direction so that the laminated divided annular portion 11a is annular, Each lamination protrusion part 11c has a site | part which protrudes to radial inside rather than the circle C1. Similarly, as shown in FIG. 5B, when the twelve second laminated members 12 punched and formed as described above are arranged so that the laminated divided annular portion 12a has an annular shape, The protrusion 12c has a portion that protrudes radially inward from the circle C1. The amount of protrusion of the stacked protrusions 11c and 12c inward in the radial direction of the circle C1 is, for example, an amount that is within the radial width of the case 1 in the air gap G (see FIG. 1).

  The first laminated member 11 and the second laminated member 12 punched and formed as described above are alternately laminated in the plate thickness direction. The divided core 5 is formed by caulking and integrating the laminated first laminated member 11 and second laminated member 12 in the axial direction.

  Next, an arrangement process for assembling the twelve divided cores 5 is performed. In this arrangement step, the twelve divided cores 5 include the first laminated member 11 in each divided core 5 and the arc convex portions 11d and 12d of the second laminated member 12 so that the first laminated member 11 in the adjacent divided core 5 and The second laminated member 12 is fitted into the circular arc recesses 11e and 12e, respectively. Thereby, the 12 division | segmentation cores 5 are connected so that rotation is possible. Insulators 14 are attached to the twelve divided cores 5 connected from both sides of the first laminated member 11 and the second laminated member 12 in the lamination direction.

  Next, a winding process is performed in which the winding 15 is wound around each of the teeth 5b from above the insulator 14. In this winding step, the twelve divided cores 5 constituting the stator core 4 are arranged so that the teeth 5b are parallel and the divided annular portion 5a is substantially linear. In this state, the winding 15 is wound around each tooth 5b.

  Next, a shaping process for shaping the 12 divided cores 5 around which the windings 15 are wound is performed. The divided core 5 around which the windings 15 are wound is rounded so that the tip of the tooth 5b faces the inner side in the radial direction of the annular portion 4a, so that the twelve teeth 5b are radial, and twelve divided annular shapes are formed. The portion 5a is shaped so as to form a cylindrical annular portion 4a. Then, the twelve shaped divided cores 5 are integrated by welding or the like. A stator core 4 composed of 12 divided cores 5 is press-fitted and fixed in the case 1. When the stator core 4 is press-fitted and fixed in the case 1, the case 1 prevents the adjacent divided cores 5 from being separated in the circumferential direction.

Next, the correction process which corrects the front-end | tip shape of each teeth 5b using the said core correction apparatus 21 is performed.
Here, as for the 1st lamination member 11 and the 2nd lamination member 12 which constitute division core 5, tip surface 11g, 12g of the 1st lamination teeth part 11b and the 2nd lamination teeth part 12b is seen from the plate thickness direction, respectively. Thus, the stator core 4 is formed to have a circular arc shape having the curvature radii R1 and R2 smaller than the value obtained by dividing the reference dimension Ds of the inner diameter of the stator core 4 by 2. Further, each of the first and second laminated members 11 and 12 is arranged in the circumferential direction so that each of the twelve first and second laminated members 11 and 12 is arranged so that the laminated divided annular portions 11a and 12a are annular. In this case, the center portions in the circumferential direction of the tip surfaces 11g and 12g are formed so as to be disposed on a circle C1 having a diameter having the same length as the reference dimension Ds. Therefore, in the stator core 4 constituted by the first laminated member 11 and the second laminated member 12 as described above, as shown in FIG. 6A, all the protruding portions 5c are radially inward from the circle C1. It will have a protruding part. In the correction step, the protruding portion 5c having a portion protruding radially inward from the circle C1 is corrected.

  In the correction process, as shown in FIG. 3, first, the case 1 to which the stator core 4 is press-fitted and fixed is inserted and fixed in the fixed recess 22a until the bottom of the case 1 comes into contact with the bottom surface of the fixed recess 22a. At this time, the stator core 4 includes the protruding portion 5c having a portion protruding radially inward from the circle C1 as described above. The case 1 inserted into the fixed recess 22a cannot be rotated in the circumferential direction with respect to the turntable 22, and cannot be moved in the axial direction. At this time, the correction tool 23 has a distance greater than the axial length of the case 1 between the end surface of the correction tool 23 on the turntable 22 side and the end surface of the turntable 22 on the correction tool 23 side. It is arranged at the position. In FIGS. 3 and 4, the insulator 14 and the winding 15 are omitted.

  Next, the control device 26 causes the turntable drive device 24 to rotate the turntable 22. When the turntable 22 rotates, the case 1 rotates in the circumferential direction together with the turntable 22. Then, the control device 26 causes the correction tool driving device 25 to slide the correction tool 23 toward the turntable 22 along the axial direction of the slide shaft 31.

  When the correction tool 23 is slid and inserted into the stator core 4, the outer peripheral surface of the roller 33 comes into contact with the tip surface 5d of the tooth 5b including the protruding portion 5c. At this time, since the stator core 4 rotates together with the case 1, each roller 33 rotates in the circumferential direction about the central axis of the roller 33 as a rotation axis by the frictional force with the tip surface 5d of the tooth 5b. Further, since the stator core 4 rotates together with the case 1, the rollers 33 are sequentially brought into contact with the front end surfaces 5d of the teeth 5b. Since the length of the outer diameter D1 of the straightening tool 23 including the roller 33 is equal to the reference dimension Ds of the inner diameter of the stator core 4, the reference dimension Ds at each protrusion 5c formed at the tip of each tooth 5b. The portion protruding radially inward from the circle C1 having the same length diameter is pressed radially outward by the roller 33. At this time, since the slot 13 that is a space exists outside the protruding portion 5 c in the radial direction, the protruding portion 5 c is easily deformed by a load applied from the roller 33. On the other hand, since the center portion in the circumferential direction of the tooth 5b is on the circle C1, and further, the divided annular portion 5a and the case 1 exist on the radially outer side of the tooth 5b, the center portion in the circumferential direction of the tooth 5b. Is not easily deformed by a load applied from the roller 33. Accordingly, as shown in FIGS. 6A and 6B, when the roller 33 rotates and moves in the circumferential direction while contacting the tip surface 5d of the tooth 5b, the roller 33 presses radially outward. The projected portion 5c is plastically deformed. As a result, the tip surface 5d of each tooth 5b has a reference radius Ds of the inner diameter of the stator core 4 from the curvature radius R3 in which the curvature radius of the tip surface 5d viewed from the axial direction is the same value as the curvature radii R1 and R2. The radius of curvature R4 is a value equal to the value obtained by dividing the value by 2.

  Then, when the correction tool 23 is gradually slid with respect to the rotating turntable 22 so as to approach the turntable 22, the portion of the tip surface 5d of the tooth 5b including the protruding portion 5c is in contact with the roller 33. Sequentially, it is deformed into an arc having a radius of curvature R4. When the correction tool 23 is moved to the turntable 22 side until the end face on the turntable 22 side of the 11 rollers 33 exceeds the end face on the bottom side of the case 1 in the stator core 4, the tip face 5d of each tooth 5b. The whole is deformed by the straightening tool 23 into an arc shape having a radius of curvature R4 when viewed from the axial direction. Thereby, the stator 2 is completed.

  Next, the control device 26 causes the correction tool driving device 25 to slide the correction tool 23 along the central axis of the slide shaft 31 so as to move away from the rotation table 22 while the rotation table 22 is rotated. And the control apparatus 26 is a position where the distance more than the length of the axial direction of case 1 is ensured between the end surface by the side of the turntable 22 of the correction tool 23, and the end surface by the side of the correction tool 23 of the turntable 22. When the correction tool 23 is arranged, the rotary table driving device 24 stops the sliding movement of the correction tool 23. Further, the control device 26 causes the turntable driving device 24 to stop the turntable 22. Then, the case 1 in which the completed stator 2 is press-fitted and fixed is removed from the turntable 22.

As described above, according to the present embodiment, the following actions and effects are obtained.
(1) The protruding portion 5c of the split core 5 formed in the split core forming step is closer to the side where the rotor 3 is disposed than the circle C1 having a diameter equal to the reference dimension Ds of the inner diameter of the stator core 4. That is, it has a portion protruding radially inward. Accordingly, all the protruding portions 5c in the teeth 5b of the stator core 4 shaped in the shaping step have a portion protruding radially inward from the circle C1. Therefore, in the correction process, since all the protrusions 5c can be pressed radially outward by the correction tool 23, it is possible to prevent the occurrence of protrusions that are not corrected as in the prior art. As a result, all the protrusions 5c can be pressed radially outward by the correction tool 23 so that the tip surface 5d of the tooth 5b can be shaped along the circle C1, so that the inner periphery of the stator core 4 facing the rotor 3 can be obtained. The diameter of the surface, that is, the inner diameter of the stator core 4 can be made constant in the circumferential direction.

  (2) Since the stator core 4 is rotated with respect to the correction tool 23 in the correction process, the inner diameter of the stator core 4 can be made constant in the circumferential direction with higher accuracy. As a result, the roundness of the inner diameter of the stator core 4 can be further improved.

  (3) In the straightening step, the straightening tool 23 is slid with respect to the stator core 4 along the axial direction of the stator core 4, so that the inner circumference of the stator core 4 is circulated at any part in the axial direction of the stator core 4. It can be constant in the direction.

  (4) Since the roller 33 can rotate about the central axis of the roller 33 as a rotation axis, the sliding resistance between the tip surface 5d of the tooth 5b and the roller 33 in contact with the tip surface 5d is reduced. The Therefore, when the straightening tool 23 is inserted into and removed from the stator core 4 while the stator core 4 is rotated in the circumferential direction with respect to the straightening tool 23, the straightening tool 23 is inserted into and removed from the stator core 4 as compared with the case where the roller 33 is not rotated. It can be done more easily.

  (5) Since the axial length of the roller 33 is shorter than the axial length of the stator core 4, the axial length of the roller 33 is greater than or equal to the axial length of the stator core 4. The contact area with 4 is reduced. Therefore, since the rotational torque when rotating the stator core 4 is smaller than when the length of the roller 33 in the axial direction is equal to or longer than the axial length of the stator core 4, the stator core 4 can be rotated more easily. be able to.

  (6) The correction tool 23 includes eleven rollers 33. Thus, when the number of rollers 33 is set to a number that does not match the divisor of the number of slots 13, in the correction process, the rollers 33 are prevented from falling between the protruding portions 5c adjacent in the circumferential direction, Only a part of the protrusions 5c is prevented from being biased and deformed.

In addition, you may change embodiment of this invention as follows.
In the above embodiment, the length of the roller 33 in the axial direction is shorter than the length of the stator core 4 in the axial direction, but may be longer than the length of the stator core 4 in the axial direction.

  In the above embodiment, the correction tool 23 is provided with 11 rollers 33, but the number of rollers 33 provided in the correction tool 23 is not limited thereto. The number of rollers 33 may be a number that is not a divisor of the number of slots 13 (same as the number of teeth 5b), and a plurality of rollers need only be provided. Therefore, in the above embodiment, the number of rollers 33 may be, for example, five or thirteen. If comprised in this way, the effect | action and effect similar to the effect | action and effect of (6) of the said embodiment can be acquired.

  In the above embodiment, the correction process is performed in a state where the stator 2 is press-fitted and fixed to the case 1. However, the straightening process may be performed before the stator 2 is press-fitted and fixed to the case 1. In this case, the stator 2 after the shaping process is fixed in, for example, a cylindrical jig, and the outer peripheral surface of the stator 2 is covered with the jig. In the correction step, a jig is fixed in the fixed recess 22a of the turntable 22, and the protrusion 5c is corrected as in the above embodiment. The stator 2 is removed from the jig after the correction process is completed, and is press-fitted and fixed to the case 1.

  In the above embodiment, the core correction device 21 is configured such that the turntable 22 is rotatable and the correction tool 23 is slidable. However, the core correction device 21 may be configured such that the turntable 22 does not rotate, and the correction tool 23 can be rotated and slidable. In this case, in the correction step, the correction tool 23 is rotated with respect to the stator core 4 fixed to the turntable 22, and the protrusion 5c is corrected by being slid.

  In the above embodiment, the correction tool 23 includes the roller 33. However, the correction tool 23 is, for example, a cylindrical mandrel having an outer diameter equal to the reference dimension Ds, a cylindrical ring having an outer diameter equal to the reference dimension Ds, or the like. Also good. When the straightening tool 23 is configured in this way, the accuracy of the outer diameter can be easily determined as compared with the straightening tool 23 of the above embodiment.

In the above embodiment, the motor includes twelve teeth 5b, but the number of teeth 5b may be less than twelve or more.
In the above embodiment, the motor is an inner rotor type motor. However, the present invention may be applied to an outer rotor type motor. In this case, the plurality of divided cores are shaped so that the tips of the teeth face the radially outer side of the annular portion. Further, the straightening tool is configured to have an inner diameter having a length equal to the reference dimension of the outer diameter of the stator core composed of a plurality of divided cores. In the straightening process, the stator core is inserted into the straightening tool, and the straightening tool and the stator core are rotated in the circumferential direction. As a result, the projecting portion having a portion projecting radially outward from a circle (reference circle) having a length equal to the reference dimension of the outer diameter of the stator core is pressed radially inward by the correction tool, and includes the projecting portion. The front end surface of the stator has a shape along a circle having a length equal to the reference dimension of the outer diameter of the stator core.

-In above-mentioned embodiment, although this invention was demonstrated to the stator 2 with which a motor is provided as an example, you may apply this invention not only to a motor but to the stator with which a rotary electric machine is provided.
The technical idea that can be grasped from the above embodiment and each of the above modifications will be described below.

  (A) In the method of manufacturing a core according to claim 2, the correction tool is a cylindrical mandrel having an outer diameter equal to the reference dimension. In this case, the accuracy of the outer diameter can be easily determined, for example, as compared with a correction tool including a roller for pressing the protrusion.

The radial direction sectional view of a motor. (A) is a perspective view of a division | segmentation core, (b) is a top view of a 1st laminated member, (c) is a top view of a 2nd laminated member. An axial direction sectional view showing a core straightening device roughly. The radial direction sectional view showing a core straightening device roughly. (A) is a top view of the 1st lamination member, (b) is a top view of the 2nd lamination member. (A) The top view of the stator core before correction | amendment, (b) is the top view of the stator core after correction | amendment. FIG. 7A is a plan view of a conventional stator core before correction, FIG. 7B is a partially enlarged view of FIG. 7A, FIG. 7C is a plan view of a conventional stator core after correction, and FIG. ) Partial enlarged view.

Explanation of symbols

  2 ... Stator, 3 ... Rotor, 4 ... Stator core as a core, 5 ... Divided core, 5b ... Teeth, 5c ... Projection, 5d ... Front end surface constituting opposing surface, 23 ... Correcting tool, 33 ... Roller, C1 ... A circle as a reference circle, D1 ... an outer diameter of the correction tool, Ds ... a reference dimension.

Claims (8)

A plurality of split cores each including a tooth and a protrusion protruding in the circumferential direction from the tip of the tooth, and a core formed by arranging the teeth in a circumferential direction so that the teeth are radial. A stator manufacturing method in which an opposing surface that is radially opposed to the rotor is formed by a tip surface of the teeth,
When the divided cores are arranged in the circumferential direction, the projecting portion projects from the reference circle having a diameter equal to the reference dimension of the diameter of the facing surface to the side where the rotor is disposed. A split core forming step of forming the split core to have,
A plurality of the divided cores are arranged in the circumferential direction so that the teeth are radial, and a shaping step of shaping the core into a ring shape,
A pressing step of pressing the protruding portion toward the base end side of the teeth with a correcting tool, and a correcting step of forming the facing surface along the circle;
A stator manufacturing method comprising: In the manufacturing method of the stator according to claim 1,
In the shaping step, the plurality of divided cores are shaped so that the tips of the teeth face radially inward,
In the straightening step, the straightening tool having an outer diameter equal to the reference dimension is inserted inside the core in the radial direction, the core and the straightening tool are relatively rotated in the circumferential direction, and the straightening tool is used. A method of manufacturing a stator, wherein the protrusion is pressed radially outward. In the manufacturing method of the stator according to claim 1,
In the shaping step, the plurality of divided cores are shaped such that the tips of the teeth face radially outward,
In the straightening step, the core is inserted into the straightening tool having an inner diameter equal to the reference dimension, the core and the straightening tool are rotated relative to each other in the circumferential direction, and the protrusion is formed by the straightening tool. A method for manufacturing a stator, wherein the stator is pressed radially inward. In the stator manufacturing method according to claim 2 or 3,
In the straightening step, the straightening tool is moved relative to the core along the axial direction of the core. In the stator manufacturing method according to any one of claims 2 to 4,
The straightening tool includes a plurality of rollers that are formed in a cylindrical shape extending along the axial direction of the core and are spaced apart in the circumferential direction, and the plurality of rollers have their central axes as rotational axes. Is held rotatably,
In the straightening step, the roller presses the protruding portion toward the base end side of the teeth. In the manufacturing method of the stator according to claim 5,
The length of the roller in the axial direction is shorter than the length of the core in the axial direction. In the manufacturing method of the stator according to claim 5 or 6,
The core formed in the shaping step has a gap between the protrusions adjacent in the circumferential direction,
The method of manufacturing a stator, wherein the straightening tool includes a number of rollers that do not match a divisor of the number of teeth provided in the core. A plurality of split cores each including a tooth and a protrusion protruding in the circumferential direction from the tip of the tooth, and a core formed by arranging the teeth in a circumferential direction so that the teeth are radial. A stator configured to have a facing surface radially opposed to the rotor by a tip surface of the teeth,
The projecting portion has a portion projecting to a side where the rotor is arranged with respect to a reference circle having a diameter equal to a reference dimension of the facing surface.

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