JP2007181348A - Method for manufacturing stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a stator in an induction motor capable of easily attaining the target running torque by improving a space factor of a main coil and capable of facilitating production in relatively few manhours. <P>SOLUTION: Main coils 6, 7 and an auxiliary coil 8 in the predetermined shape are previously produced by winding coil wires to be shaped in a die of the predetermined shape. A stator core body 1 is formed with multiple teeth 3 installed in a protruding manner in the outer circumference of a doughnut-shaped portion 2. A synthetic resin insulating layer 4 is formed at least on the inside and on both sides of the teeth 3 of the stator core body 1. The main coils 6, 7 and the auxiliary coil 8 are fitted into slots 3a between the teeth 3 of the stator core body 1 from the outside, thereby fitting a ring-shaped yoke core 9 into the outer circumference of the edge portions of the teeth 3 of the stator core body 1. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a stator in an induction motor, and more particularly to a method of manufacturing a stator that can easily manufacture a stator of a high-performance induction motor with less man-hours.

  A stator core of an induction motor stator is generally formed by projecting a large number of teeth inwardly from a ring-shaped yoke located on the outermost periphery, and wound in advance in a slot formed between the teeth. The stator is manufactured by fitting the stator coil wound around the frame into the teeth, or winding the coil directly around the teeth (see, for example, Patent Document 1 below).

However, a conventional stator of this type of induction motor has a structure in which a coil is directly wound around a tooth protruding from the inside of a stator core, or a stator coil pre-wound around a winding frame is inserted and mounted. In both cases, the space between the tips of the teeth is limited in both cases. As the number of teeth and slots increases, the space for winding the coil is reduced and the number of coil windings is limited. Or, the number of slots and the number of teeth are limited, and there is a problem that the target performance of the electric motor cannot be achieved.
JP-A-8-308189 JP 2003-284270 A

  On the other hand, a stator of a conventional induction motor uses a stator core having a structure in which a large number of teeth protrude from the outer periphery of a ring-shaped yoke as described in Patent Document 2 above, and coils are directly connected to these teeth. A structure that is wound around is known. Since this type of stator core protrudes so that the teeth open outward on the outer periphery of the ring-shaped yoke, it can be wound relatively easily when the coil is wound around the teeth with a winding machine or the like. When the coil is wound in the slot between the teeth by the distributed winding method, the main coil is wound around the outside of the auxiliary coil, so that the coil end becomes long and the space factor of the main coil decreases, and the desired coil There was a problem that it was difficult to obtain rotational torque. In addition, the coil end needs to be shaped, and a lot of man-hours are spent on shaping the coil end. At the time of shaping, there is a problem that the insulation of the coil is easily impaired.

  The present invention solves the above-described problems, and can improve the space factor of the main coil to easily obtain a target rotational torque, and can be easily manufactured with relatively few man-hours. An object of the present invention is to provide a method for manufacturing a stator in an induction motor.

  To achieve the above object, a stator manufacturing method of the present invention is a stator manufacturing method for an induction motor in which a main coil and an auxiliary coil are wound between slots of a stator core. The main coil and auxiliary coil of a predetermined shaping shape are pre-manufactured by winding while shaping, and the stator core body formed by projecting a large number of teeth on the outer periphery of the annular part is synthesized on at least the inner surface and both side surfaces of the teeth A resin insulating layer is formed, and a ring-shaped yoke core is fitted and fixed to the outer periphery of the tip end portion of the teeth of the stator core body in a state where the main coil and the auxiliary coil are fitted from the outside into slots between the teeth in the stator core body. It is characterized by that.

  Here, a bulge is provided on both sides of the tip of the tooth to form a substantially T-shape, and the opening of the slot is fitted in the slot between the teeth from the main coil and the auxiliary coil. The main coil or the auxiliary coil can be fixed by press-fitting a closing plate between the bulging portions so as to close the main coil.

  In addition, insulating sleeves made of synthetic resin can be formed on both side surfaces of the annular portion of the stator core body.

  The main coil is formed of a large-diameter main coil and a small-diameter main coil, and the small-diameter main coil is concentric with the large-diameter main coil and is fitted into another slot located inside the large-diameter main coil. Thus, the coil ends of the two coils can be mounted so as to substantially overlap each other in the axial direction of the stator core body.

  The insulating layer can be formed by insert molding of a synthetic resin using the stator core body as an insert. Alternatively, the insulating layer formed by molding a synthetic resin into the outer shape of the stator core body is divided, and the divided body is formed. It can also be formed by fitting to the outer surface of the stator core.

  According to the method of manufacturing a stator having the above-described configuration, a coil wire is preliminarily wound while being shaped into, for example, a predetermined-shaped winding frame, and a main coil and an auxiliary coil having a predetermined shape are manufactured. The stator core body that is widely open in the outer peripheral direction is fitted so that it is fitted from the outside between the slots between the teeth of the stator core body, so that the assembly work of the coil is extremely good, and the number of slots is up to the maximum The number of slots can be increased, and a reduction in rotational torque due to the reduction in the number of slots can be avoided, and a high-performance induction motor can be manufactured.

  Furthermore, since the coil to be mounted is shaped in advance, it can be easily and efficiently assembled between the slots without applying unnecessary force to the coil and without damaging the main coil and the auxiliary coil. Further, the main coil and the auxiliary coil can be shaped to be effectively accommodated in the slot, so that the space factor of the main coil can be increased and the height of the coil end can be minimized.

  Further, it is not necessary to shape the coil end after winding the coil as in the case where the coil is wound directly on the teeth, and there is no possibility of damaging the coil end by the shaping operation. In addition, since an insulating layer of synthetic resin is formed in advance on the inner side surface and both side surfaces of each tooth of the stator core, the main coil and auxiliary coil previously wound in a shaped shape are insulated with varnish, insulating paper, etc. There is no need to perform the operation, and the number of work steps can be reduced.

  Furthermore, when a synthetic resin insulation sleeve is formed on both sides of the annular part of the stator core body, the coil end is satisfactorily held along the insulation sleeve, and the coil end connection part is also attached to the insulation sleeve. Can be retained.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a front view of a stator core body 1 in an induction motor stator, FIG. 2 is a perspective view thereof, and FIG. 3 is a perspective view of the stator core body 1 in which an insulating layer 4 is formed at a predetermined portion of a tooth 3. ing.

  Here, as an example, 24 slots 3a are provided on the circumference of the stator core, and a large-diameter main coil 6, a small-diameter main coil 7, and an auxiliary coil 8 that are formed in a predetermined shape in advance are inserted into the slots 3a. Although a stator having four magnetic poles will be described, the present invention can be applied to a stator having a slot number or magnetic pole number other than this.

  As shown in FIGS. 1 and 2, the stator core body 1 has 24 teeth 3 protruding from the outer peripheral portion of the ring-shaped annular portion 2 at an angular interval of 15 °, and the teeth 3 and the teeth 3 on the entire periphery. A large number of laminated steel plates are laminated so that 24 slots 3a are provided therebetween.

  As shown in FIG. 3, an insulating layer 4 made of synthetic resin is formed on all surfaces except the inner peripheral surface of the annular portion 2 of the stator core body 1 and the tip surfaces of all the teeth 3. That is, the insulating layer 4 made of synthetic resin is formed on the inner side surface (surface on which the slot 3a is located) and both side surfaces (front and back in FIG. 1) of all teeth 3 of the stator core body 1. This insulating layer 4 of synthetic resin can be molded by insert molding, for example, by placing the stator core body 1 as an insert in a mold having a predetermined shape, and injecting a thermoplastic resin such as PVC into the mold. it can.

  At the time of molding, the insulating sleeve 4 and the cylindrical insulating sleeve 5 are integrally molded so as to protrude from both side surfaces (front and back in FIG. 1) of the annular portion 2 of the stator core body 1. The insulating sleeve 5 is provided so as to project from both sides in order to hold the coil ends of the large-diameter main coil 6, small-diameter main coil 7 and auxiliary coil 8 fitted in the slot 3a on the circumference. Further, as will be described later, a plurality of coil holding pins are fixed to the end surface of the insulating sleeve 5 so as to insert the tips, and used to connect and hold the ends of the coils.

  The insulating layer may be formed by dividing the outer shape of the stator core body 1 by molding a synthetic resin and fitting the divided body to the outer surface of the stator core.

  Here, as an example, the coils used for the stator are three types, that is, a large-diameter main coil 6, a small-diameter main coil 7, and an auxiliary coil 8. Since the stator has 4 poles and the stator core has 24 slots, as shown in FIG. 11, the 4 poles are positioned at 0 °, 90 °, 180 °, and 270 °, respectively, as seen from the front of the stator. When formed, the large-diameter main coil 6 and the small-diameter main coil 7 are arranged concentrically on each magnetic pole, and the auxiliary coil 8 is arranged so as to straddle each of these magnetic poles.

  That is, as shown in FIG. 11, for example, in the case of the magnetic pole at the 0 ° position, the large-diameter main coil 6 is mounted so as to straddle between the 37.5 ° slot and the 322.5 ° slot. Is mounted across the 22.5 ° slot and the 337.5 ° slot. The auxiliary coil 8 is mounted so as to straddle between the 7.5 ° slot and the 82.5 ° slot. That is, the center of the auxiliary coil 8 is mounted with a 45 ° shift from the center of the main coil.

  Thus, the winding shape and size of the large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 that are fitted and mounted in each slot 3a of the stator core body 1, the bending shape when fitted in the slot, Since the flat shape and the like are determined in advance based on the size, thickness, shape, and the like of each slot 3a of the stator core body 1, the large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 are Using a winding frame formed according to the winding shape, size, flat shape, etc., it can be manufactured by being wound into a predetermined number of turns while being formed into a unique shaping shape.

  Therefore, the four large-diameter main coils 6, the four small-diameter main coils 7 and the four auxiliary coils 8 used in the four-pole stator are formed using the above-described winding frame. As shown in FIGS. 4, 5, and 6, each side can be curved into a predetermined rectangular shape and shaped while adjusting the outer diameter and flatness of each side, and can be manufactured in advance. In particular, each large diameter main coil 6, small diameter main coil 7 and auxiliary coil 8 are inserted into the slot 3a in a flat shape so that they can be easily inserted into the slot 3a. The large-diameter main coil 6 is shaped into a shape that fits inside. Further, as shown in FIG. 8 and the like, the coil ends of the large-diameter main coil 6 and the auxiliary coil 8 are overlapped with each other, and this intersecting portion is flat in the circumferential direction (radial direction). In other words, the coil ends of the large-diameter main coil 6 and the auxiliary coil 8 are formed in a cross-sectional shape that is clearly different from the cross-sectional shape in the slot, and prevents the coil ends of both coils from expanding. ing.

  Furthermore, by winding each large-diameter main coil 6, small-diameter main coil 7 and auxiliary coil in a predetermined shaping shape, it is not necessary to shape the coil when each coil is inserted into the slot. Since the insulating layer 4 is formed on the inner surface of the slot of the stator core body 1 as described above, the process of applying varnish or insulating paper to the coil can be omitted.

  Further, since the large diameter main coil 6 or the small diameter main coil 7 is mounted so as to overlap or intersect with the auxiliary coil 8, the space factor in the slot tends to decrease due to interference of the auxiliary coil 8. The large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 are wound by shaping their winding shapes so that the large-diameter main coil 6 or the small-diameter main coil 7 is not affected by the auxiliary coil 8. To do. Thereby, the space factor of the large diameter main coil 6 and the small diameter main coil 7 can be made high, and also the height shape of the coil end of each coil can be suppressed to the minimum.

  Next, the stator core body 1 manufactured in advance as described above and provided with the insulating layer 4, the large-diameter main coil 6, the four small-diameter main coils 7, and the four auxiliary coils 8 are used. Assemble.

  First, the four auxiliary coils 8 are inserted (inserted) between the slots 3a of the stator core body 1 so as to straddle the magnetic pole positions. As shown in FIG. 3, since each slot 3a of the stator core body 1 is opened toward the outer peripheral direction, the auxiliary coil 8 can be inserted into the slot 3a at a predetermined position very easily with almost no force. be able to. For example, as shown in FIG. 11, one auxiliary coil 8 is mounted so as to straddle between a 7.5 ° slot and an 82.5 ° slot.

  In the state where the four auxiliary coils 8 are inserted between the slots 3a of the stator core body 1 so as to straddle the magnetic pole positions, the four large-diameter main coils 6 are then centered at the central positions of the magnetic poles. As shown in FIG. 8, it is inserted into each slot 3a so as to match the parts. In the insertion operation of the large-diameter main coil 6, each slot 3a of the stator core body 1 is opened in the outer circumferential direction, so that it can be inserted very easily into the predetermined slot 3a with almost no force. . For example, as shown in FIG. 11, one large-diameter main coil 6 is inserted so as to straddle between a 37.5 ° slot and a 322.5 ° slot.

  The four large diameter main coils 6 are inserted into the slots 3a concentrically with the center positions of the magnetic poles, and then the four small diameter main coils 7 are concentric with the center positions of the magnetic poles. As shown in FIG. 8, it is inserted into each slot 3a. In the operation of inserting the small-diameter main coil 7, each slot 3a of the stator core body 1 is opened in the outer peripheral direction, so that it can be inserted very easily into the predetermined slot 3a with almost no force. For example, as shown in FIG. 11, one small-diameter main coil 7 is mounted so as to straddle between a 22.5 ° slot and a 337.5 ° slot.

  In this way, all the large-diameter main coils 6, small-diameter main coils 7, and auxiliary coils 8 are inserted into the slots 3a of the stator core body 1 and mounted, but the illustration is omitted. A wedge member is inserted from the tip side between the tip portion and the inside of each coil, and each coil is fixed to the core. The wedge member can be shaped to be fitted to the tip of each tooth 3.

  Then, as shown in FIG. 9, a ring-shaped (cylindrical) yoke core 9 is fitted and fixed to the outer peripheral portion of the stator core body 1 on which the coils are mounted as described above. The yoke core 9 can be attached to the outer peripheral portion of the stator core body 1 by press-fitting, for example, the tips of the teeth 3 to the inner peripheral surface of the yoke core 9.

  Thereafter, the ends of all the large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 are connected in accordance with the order of the connection circuit. Each end of the connected coils is, for example, a core A plurality of coil holding pins are fixedly attached to the end faces of the insulating sleeve 5 protruding on both sides of the sleeve, and the coil holding pins are held so that each end of the coil is entangled, thereby completing the stator. To do.

  Thus, according to the stator manufacturing method described above, the large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 that have been wound in a predetermined shaping shape in advance are inserted into the slot 3a that opens in the outer circumferential direction. Therefore, the coil can be attached to the stator core very easily without applying force, and the problem of damaging the coil during the attaching operation can be prevented. Further, the number of slots can be increased to the maximum, and a high-performance induction motor can be manufactured while avoiding a decrease in rotational torque due to the reduction in the number of slots.

  Furthermore, since the coil to be mounted is shaped in advance, it can be easily and efficiently assembled between the slots without applying unnecessary force to the coil and without damaging the main coil and the auxiliary coil. The large-diameter main coil 6, the small-diameter main coil 7 and the auxiliary coil 8 are shaped so as to be effectively housed in the slots, thereby increasing the space factor of the main coils 6 and 7 and minimizing the height of the coil ends. It can be.

  Further, it is not necessary to shape the coil end after winding the coil as in the case where the coil is wound directly on the teeth, and there is no possibility of damaging the coil end by the shaping operation. Further, since the insulating layer 4 of synthetic resin is formed in advance on the inner side surface and both side surfaces of each tooth 3 of the stator core, the large-diameter main coil 6, the small-diameter main coil 7, and the auxiliary coil 8 that are previously wound in a shaped shape. Therefore, it is not necessary to apply an insulator such as varnish or insulating paper, and the number of work steps can be reduced.

  Further, when the synthetic resin insulating sleeves 5 are formed on both side surfaces of the annular portion 2 of the stator core body 1, the coil ends are satisfactorily held along the insulating sleeve 5, and the coil end connecting portions are also insulated sleeves. 5 can be held together.

  In addition, at the tip of each tooth 3 of the above-described embodiment, a bulging portion spreading on both sides is provided to form a substantially T shape, and after winding the coil around the slot between the teeth, the opening of the slot 3a is closed. It is also possible to prevent the coil from coming off by fitting the closing plate inside the bulging portion and pushing the coil into the slot 3a.

  The large-diameter main coil 6, the small-diameter main coil 7 and the auxiliary coil 8 are shaped in a predetermined shape by winding a wire around a winding frame formed in a predetermined shape. Each coil can be manufactured by winding the wire and shaping it into a predetermined shape by pressing.

It is a front view of the stator core main body which shows one Embodiment of this invention. It is a perspective view of the stator core main body. It is a perspective view of a stator core body in a state where an insulating layer and an insulating sleeve are covered and formed. It is the front view (a) and left view (b) of a large diameter main coil. It is the front view (a) and left view (b) of a small diameter main coil. It is the front view (a) and left view (b) of an auxiliary coil. It is a front view of the state which piled up each coil. It is a perspective view of the state which inserts a small diameter main coil in a stator core main body. It is a perspective view which shows the state which fits a yoke core to the outer peripheral part of the stator core main body which mounted | wore the coil. It is a perspective view of the manufactured stator. It is a section explanatory view in the state where a coil was wound around a stator core body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator core main body 2 Annular part 3 Teeth 3a Slot 4 Insulating layer 5 Insulating sleeve 6 Large diameter main coil 7 Small diameter main coil 8 Auxiliary coil 9 York core

Claims (7)

In a method of manufacturing a stator for an induction motor in which a main coil and an auxiliary coil are wound between slots of a stator core,
In the teeth of the stator core body formed by winding a coil wire while shaping it into a mold of a predetermined shape to produce a main coil and an auxiliary coil of a predetermined shape in advance and projecting a large number of teeth on the outer periphery of the annular portion An insulating layer of synthetic resin is formed on at least the inner surface and both side surfaces, and the main coil and the auxiliary coil are fitted from the outside into the slots between the teeth in the stator core body, on the outer periphery of the tips of the teeth of the stator core body. A stator manufacturing method, wherein a ring-shaped yoke core is fitted and fixed.  Protruding portions are provided on both sides of the tip of the teeth to form a substantially T shape, and the opening of the slot is closed with the main coil and the auxiliary coil fitted from the outside into the slots between the teeth. The stator manufacturing method according to claim 1, wherein the main coil or the auxiliary coil is fixed by press-fitting a closing plate between the bulging portions.  2. The method of manufacturing a stator according to claim 1, wherein an insulating sleeve made of a synthetic resin protrudes integrally with the insulating layer on both side surfaces of the annular portion of the stator core body.  The main coil is formed of a large-diameter main coil and a small-diameter main coil, and the small-diameter main coil is fitted into another slot located concentrically with the large-diameter main coil and inside the large-diameter main coil, The stator manufacturing method according to claim 1, wherein the coil ends of the two coils are mounted so as to substantially overlap each other in the axial direction of the stator core body.  The method for manufacturing a stator according to claim 1, wherein the insulating layer is formed by insert molding of a synthetic resin using the stator core body as an insert.  2. The stator according to claim 1, wherein the insulating layer is formed by dividing the outer shape of the stator core body formed by molding a synthetic resin and fitting the divided body to the outer surface of the stator core. 3. Production method. In a method of manufacturing a stator for an induction motor in which a main coil and an auxiliary coil are wound between slots of a stator core,
A stator core body formed by forming a main body and an auxiliary coil in advance by shaping a coil body in which a coil wire is wound to a predetermined diameter into a predetermined shape by pressing, and projecting a large number of teeth on the outer periphery of the annular portion. An insulating layer of synthetic resin is formed on at least the inner side surface and both side surfaces of the teeth, and the tips of the teeth of the stator core body are fitted in the state where the main coil and the auxiliary coil are fitted into the slots between the teeth in the stator core body. A stator manufacturing method, wherein a ring-shaped yoke core is fitted and fixed to the outer periphery of the stator.

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