JP2007244069A - Manufacturing method of stator core and stator core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator core achieved in the high output of a motor and improved in the efficiency of the motor by making the thickness of a laminated layer of the stator core thicker while not changing the total length of the motor of a conventional structure. <P>SOLUTION: The stator core 1 is formed into a cylindrical shape having a coil accommodation groove 2 formed thereon, and comprises: coil ends 4A, 4B that are inserted into the coil accommodation part from above insulating paper 3, and formed into prescribed shapes at their extruded parts that are excluded from the coil accommodation part; an annular coil 4 having an air gap 7 between the coil ends and the stator core; divided stator cores 8 that are formed by being divided into a plurality of pieces whose combined plane shapes are almost the same with the upper-end face shape and the lower-end face shape of the stator core; and a motor case 12 in which the stator core to which the divided stator cores are attached is inserted, and fixes the stator core. The divided stator cores are arranged on the upper-end face and the lower-end face of the stator core so that each of the divided stator cores 8 is inserted into the air gap 7. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a stator core constituting a rotary electric motor and a stator core.

  For example, a stator core of a rotary electric motor is a coil housing of a stator core formed by laminating a plurality of silicon steel plates having a thickness of about 0.3 to 0.5 mm, and coils and wedges wound in an annular shape in advance. It is manufactured by being inserted into the groove.

  The end portion (coil end portion) of the coil that protrudes outward from the coil housing groove portion is pressed in the axial direction of the stator core to be small after regulating the inner diameter and the outer diameter in order to reduce the size of the motor.

When forming the coil end part, in order to prevent the insulating material (insulating paper) and the coil from being damaged by the corners of the coil receiving groove part, and to prevent an electrical short circuit between the stator core and the coil, a cuff support jig is used. By inserting between the stator core and the coil, a gap portion for securing an insulation distance is formed in the coil end portion (see, for example, Patent Document 1).
JP 2005-110435 A

  By the way, in recent years, miniaturization, high output, and high efficiency of motors are required. In order to satisfy these requirements, it is desirable to apply a large pressure to the coil end portion to form the coil end portion small.

  However, if a large pressure is applied to the coil end, the insulating film covering the electric wire may be damaged.

  Further, when the motor is reduced in length by reducing the overall length of the motor, it is necessary to reduce the stack thickness of the stator core. However, if the lamination thickness of the stator core is reduced, the output as a motor is reduced, and high output is prevented. In addition, since the circumference of the coil increases (electrical resistance increases) with respect to the core lamination thickness, which is a path for the magnetic flux that changes the current into the rotational torque, the motor efficiency also deteriorates. For this reason, it is possible to reduce the size of the coil end portion and improve the efficiency by inserting a coil having a short circumference relative to the core lamination thickness, but if the circumference is too short, coil insertion will not be possible. It becomes difficult to cause elongation of the electric wire, scratching of the electric wire film, crushing of the wedge and the like.

  Therefore, the present invention increases the stator core lamination thickness while keeping the same overall motor length of the conventional structure to increase the motor output, and shortens the coil peripheral length to reduce the coil electrical resistance with respect to the stator core lamination thickness. Thus, an object of the present invention is to provide a stator core manufacturing method and a stator core in which the motor efficiency can be increased and the motor itself can be reduced in size by designing the cooling system to be smaller by improving the motor efficiency.

  According to the stator core manufacturing method of the present invention, after the insulating paper is disposed in each coil housing groove formed in the cylindrical stator core, the annular coil is inserted into the coil housing groove, and from both ends of the coil housing groove. Forming both ends of the coil projecting outward into a predetermined shape to form a coil end, and forming a gap between both ends of the coil and the end surface of the stator core, and a plane when combined Each of the divided stator cores divided into a plurality of shapes whose shape is substantially the same as the shape of the upper end surface and the lower end surface of the stator core is inserted into the gap portion formed in the coil end portion. The step of disposing each on the upper end surface and the lower end surface and the stator core to which the divided stator core is attached are inserted into the motor case. And a step of fixing.

  The stator core according to the present invention includes a cylindrical stator core having a plurality of coil housing groove portions formed on the inner surface, insulating paper disposed in each coil housing groove portion, and inserted into the coil housing groove portion from above the insulating paper. When combined with a coil end portion formed by molding a portion protruding outward from the groove portion into a predetermined shape, and an annular coil having a gap portion between the coil end portion and the stator core A divided stator core having a planar shape divided into a plurality of shapes substantially the same as the shape of the upper end surface and the lower end surface of the stator core, and a motor case for inserting and fixing the stator core to which the divided stator core is attached. Each of the split stator cores is inserted into the gap formed in the coil end portion. It is arranged at the upper end and lower end surfaces of the core.

  According to the stator core manufacturing method of the present invention, the split stator core provided separately from the cylindrical stator core is disposed on the upper end surface and the lower end surface of the stator core after inserting the coil into the coil receiving groove of the stator core. When the coil is inserted, the core lamination thickness is small with respect to the coil circumferential length. Therefore, the pressure applied to the coil when the coil is inserted is reduced, and damage to the insulating film of the coil can be reduced. As a result, improvement in quality can be enhanced and coil insertion work can be facilitated.

  Moreover, according to the method of the present invention, since the coil can be easily inserted into the coil housing groove, the cross-sectional area of the electric wire that can be inserted into the coil housing groove can be increased, thereby reducing the electrical resistance of the coil itself. And motor efficiency can be increased.

  According to the stator core of the present invention, since the divided stator core prepared separately from the stator core is arranged on the upper end surface and the lower end surface of the cylindrical stator core in which the coil is inserted and arranged through the insulating paper, With the split stator core arranged on the stator core having the shape, the core lamination thickness can be increased while keeping the same overall length of the motor. As a result, it is possible to increase the output of the motor.

  Further, according to the stator core of the present invention, the coil peripheral length can be shortened with respect to the core lamination thickness, the electric resistance of the coil can be reduced, and the motor efficiency can be increased. Furthermore, since the motor efficiency can be increased, the cooling system can be designed to be small, and the motor can be downsized and the entire system can be downsized.

  Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings.

"Manufacturing method of stator core"
First, a method for manufacturing the stator core of the present embodiment will be described. 1 shows a manufacturing process of a stator core, a process chart for preparing a stator core, insulating paper, and a coil, FIG. 2 shows a manufacturing process of the stator core, a process chart for inserting the coil into the coil housing groove, and FIG. 3 shows a manufacturing process of the stator core. FIG. 4 shows a process for preparing a split stator core, FIG. 4 shows a manufacturing process for the stator core, a process diagram for arranging the split stator core on the upper end surface and the lower end surface of the cylindrical stator core, and FIG. 5 shows a manufacturing process for the stator core. FIG. 6 shows a stator core manufacturing process, FIG. 6 shows a stator core manufacturing process, FIG. 7 shows a stator core manufacturing process, and FIG. 7 shows a stator core manufacturing process. It is process drawing which presses and fixes a division | segmentation stator core to a stator core with a ring-shaped fixing member.

  In order to manufacture a stator core, first, as shown in FIG. 1, a cylindrical stator core 1, an insulating paper 3 disposed in a coil housing groove 2 formed in the stator core 1, and a coil from above the insulating paper 3 An annular coil 4 to be inserted and fixed in the housing groove 2 is prepared.

  The stator core 1 is a cylindrical body formed by laminating a large number of thin steel plates (for example, silicon steel plates) 5 in a ring shape to have a predetermined core lamination thickness. On the inner surface of the cylindrical stator core 1, coil receiving groove portions 2 functioning as slots having a substantially U shape in plan view are formed in the circumferential direction at a predetermined interval in the height direction.

  The insulating paper 3 is disposed in the coil housing groove 2 for the purpose of ensuring insulation so that the stator core 1 and the coil 4 are not short-circuited. Therefore, the insulating paper 3 has a length that can slightly protrude outward from both ends of the stator core 1 when inserted into the coil housing groove 2 and is large enough to substantially cover the inner surface of the coil housing groove 2. ing. Further, the insulating paper 3 has a shape woven in advance according to the internal shape of the coil housing groove 2 before being inserted into the coil housing groove 2.

  On the other hand, the coil 4 is formed as an annular shape having a substantially rectangular shape in plan view by winding the wire 6. A plurality of coils 4 having an annular shape are prepared according to the characteristics of the motor.

  First, as shown in FIG. 2, the insulating paper 3 woven in a predetermined shape is disposed in the coil housing groove 2 of the stator core 1 having the cylindrical shape. Then, the insulating paper 3 covers the entire inner surface of the coil housing groove 2 with the insulating paper 3, and the ends 3 a and 3 b of the insulating paper 3 protrude outward from both ends of the coil housing groove 2. Next, the coil 4 is inserted and arranged in the coil receiving groove 2 at a predetermined position from above the insulating paper 3. Since the coil 4 is disposed in the coil housing groove 2 via the insulating paper 3, the insulation of the coil 4 is ensured with respect to the stator core 1.

  Next, both end portions of the coil 4 projecting outward from both ends of the coil housing groove portion 2 are pressed and formed into a predetermined shape to form coil end portions 4A and 4B. When pressurizing both ends of the coil, a cuff support jig (not shown) is inserted between the coil end and the stator core end faces 1a and 1b. By inserting this cuff support jig between both end portions of the coil and the stator core end surfaces 1a and 1b, a gap for ensuring insulation between the coil end portions 4A and 4B and the stator core end surfaces 1a and 1b. Part 7 is formed. The cuff support jig not only forms the gap 7 but also serves to protect the insulating paper 3 when the coil end portion is formed. When the end of the coil 4 has been formed, the end of the coil is bound with a binding thread to complete the coil end 4A, 4B.

  Next, a plurality of the divided stator cores 8 shown in FIG. 3 are arranged on the stator core end faces 1a and 1b which are the upper end face and the lower end face of the cylindrical stator core 1. Similar to the cylindrical stator core 1, the split stator core 8 is attached to the core portion 10 so as to cover a core portion 10 formed by laminating a plurality of thin steel plates 9 and at least a portion in contact with the coil 4. It consists of an insulating cover 11. As shown in FIG. 5, the divided stator core 8 is composed of a plurality of pieces, and the planar shape when the plurality of the divided stator cores are combined is substantially the same as the shape of the upper end surface and the lower end surface of the stator core 1.

  In the present embodiment, the divided stator core 8 has a shape in which the upper end surface shape and the lower end surface shape of the stator core 1 are equally divided at substantially the same pitch as that of the coil receiving groove portion 2, and the dividing position is set to the coil receiving groove portion 2. This is the groove center position. Therefore, the divided stator core 8 includes an extending portion 8A corresponding to a portion between the coil housing groove portions 2 and an arcuate portion 8B corresponding to a portion other than the coil housing groove portion 2, and is substantially T-shaped in plan view. Yes.

  The insulating cover 11 exposes the lower surface 10a in contact with the stator core end surfaces 1a and 1b of the core portion 10, the front end surface 10b of the extending portion 8A, both side surfaces 10c of the arcuate portion 8B, and the rear end surface 10d, and other portions. The shape is such that it is covered. The insulating cover 11 is formed by placing a resin material having excellent insulating properties in a mold and injection molding. By attaching the insulating cover 11 to the core portion 10, the coil 4 and the core portion 10 are formed. This ensures the insulation (prevention of short circuit) and prevents the coil 4 from being damaged. The thickness of the split stator core 8 that covers the core portion 10 with the insulating cover 11 is substantially the same height as the gap portion 7 formed in the coil end portions 4A and 4B. The split stator core 8 can be inserted.

  Next, as shown in FIGS. 4 and 5, each of the divided stator cores 8 is inserted into a gap 7 formed in the coil end portions 4A and 4B, and the stator core end surfaces which are the upper end surface and the lower end surface of the stator core 1. It arrange | positions at 1a and 1b, respectively. The plurality of divided stator cores 8 are arranged side by side on the stator core end faces 1 a and 1 b to form a ring shape and function as the stator core 1. The adjacent divided stator cores 8 are provided in contact with each other, so that the core parts 10 exposed on both side surfaces 10c of the arcuate part 8B come into contact with each other to form a magnetic circuit part.

  Next, as shown in FIG. 6, the stator core 1 to which the divided stator core 8 is attached is inserted into the motor case 12 and fixed. The motor case 12 is formed as a cylindrical body that can be fixed by press-fitting or shrink-fitting the stator core 1 therein. The motor case 12 has female screw portions 13 formed at several locations for fixing ring-shaped fixing members, which will be described later, to the upper end surface and the lower end surface, respectively.

  Finally, as shown in FIG. 7, the ring-shaped fixing member 14 is fixed to both ends of the motor case 12 with screws 15, and the split stator core 8 is separated by the core pressing portion 14 </ b> A formed on the ring-shaped fixing member 14. The stator core 1 is pressed and fixed. The ring-shaped fixing member 14 includes an annular ring portion 14B and an annular core pressing portion 14A that hangs downward from the inside of the ring portion 14B. The ring portion 14B is attached to both ends of the stator core 1 and bolts 15 are attached. Is screwed into the female screw portion 13 so that each divided stator core 8 is pressed by the annular core pressing portion 14A.

"Structure of stator core"
Briefly describing the structure of the stator core 1 configured as described above, a cylindrical stator core 1 in which a plurality of coil receiving groove portions 2 are formed on the inner surface, insulating paper 3 disposed in each coil receiving groove portion 2, and insulating paper The coil end portions 4A and 4B are formed by being inserted and disposed in the coil receiving groove portion 2 from above the portion 3 and protruding outward from the coil receiving groove portion 2 into a predetermined shape, and the coil end portions 4A and 4B. And an annular coil 4 having a gap 7 between the stator core 1 and a plane shape when combined with the stator core 1 is divided into a plurality of parts that are substantially the same as the upper end surface shape and the lower end surface shape of the stator core 1. The divided stator core 8 thus formed, and the motor case 12 that inserts and fixes the stator core 1 to which the divided stator core 8 is attached are provided.

  In the stator core 1 of the present embodiment, each of the divided stator cores 8 is arranged on the upper end surface and the lower end surface of the stator core 1 so as to be inserted into the gap portion 7 formed in the coil end portions 4A, 4B. It has become. Each of the divided stator cores 8 is fixed without being rattled by being pressed against the stator core 1 by a core pressing portion 14A of a ring-shaped fixing member 14 screwed to the stator core 1.

  In a state before the split stator core 8 is disposed (see FIG. 2), when the split stator core 8 is disposed rather than the core lamination thickness L1 of the cylindrical stator core 1 with respect to the motor full length (distance between the coil end portions 4A and 4B) L. (See FIG. 4), the core thickness L4 of the split stator core 8 is added to the motor full length L of the same length, and the total core lamination thickness L5 is correspondingly increased (L1 <L5). That is, in the stator core 1 of the present embodiment in which the divided stator core 8 is provided even with the same motor full length L, the total core lamination thickness L5 can be increased by the amount of the divided stator core 8 provided. In FIG. 2, L2 indicates the length of the coil end portions 4A and 4B, and L3 indicates the length of the gap portion 7.

  According to the stator core 1 of the present embodiment, a split stator core 8 prepared separately from the cylindrical stator core 1, and an upper end surface of the cylindrical stator core 1 in which the coil 4 is inserted and disposed through the insulating paper 3 and Since the lower end surfaces (stator core end surfaces 1a and 1b) are arranged by using the gaps 7, the cores are laminated with the same length L of the motor by the divided stator cores 8 arranged on the cylindrical stator core 1. The thickness L5 can be increased. That is, since the gap portion 7 required for securing the conventional insulation distance can be used as the stator core by the arrangement of the divided stator core 8, it is possible to increase the output of the motor.

  Further, according to the stator core 1 of the present embodiment, the coil peripheral length can be shortened with respect to the core lamination thickness L5, the electric resistance of the coil 4 can be reduced, and the motor efficiency can be increased. Furthermore, since the motor efficiency can be increased, the cooling system can be designed to be small, and the motor can be downsized and the entire system can be downsized.

  Further, according to the stator core 1 of the present embodiment, the divided stator cores 8 are collectively pressed against and fixed to the stator core 1 by the ring-shaped fixing member 14. Can be fixed to.

  Further, according to the stator core 1 of the present embodiment, the split stator core 8 is configured by the core portion 10 formed by laminating a plurality of thin steel plates and the insulating cover 11 attached to the core portion 10. Thus, the coil 4 and the core portion 10 can be more reliably insulated than the insulating paper 3 by the insulating cover 11 having excellent insulating properties.

  In addition, according to the stator core 1 of the present embodiment, the split stator core 8 is configured by the core portion 10 and the insulating cover 11 covering the core portion 10, so that the insulation process for the portions that do not require insulation from the coil 4 is omitted. In addition, the insulation process can be simplified and the cost can be reduced.

  On the other hand, according to the stator core manufacturing method of the present embodiment, the split stator core 8 provided separately from the cylindrical stator core 1 is inserted into the coil receiving groove 2 of the stator core 1, and then the stator core 1. Since the core laminated thickness L1 is small with respect to the coil circumferential length when the coil is inserted because it is arranged on each of the upper end surface and the lower end surface, the pressure applied to the coil 4 at the time of coil insertion is reduced. The damage given can be reduced. As a result, the improvement in quality can be enhanced and the insertion operation of the coil 4 can be facilitated.

  In addition, according to the stator core manufacturing method of the present embodiment, since the coil 4 can be easily inserted into the coil housing groove portion 2, the cross-sectional area of the electric wire that can be inserted into the coil housing groove portion 2 can be increased. The electric resistance of itself can be reduced, and the motor efficiency can be increased.

[Other embodiments]
Although specific embodiments to which the present invention is applied have been described above, the present invention is not limited to the above-described embodiments, and various modifications can be made.

  FIG. 8 is a perspective view showing another example of the split stator core 8. The divided stator core 8 of this embodiment is formed by coating an insulating resin on the entire surface of the core portion 10 in FIG. 3 (B) or a portion where insulation with respect to the coil 4 is required.

  As in this embodiment, if the core portion 10 is resin-coated, the split stator core 8 that can easily secure the insulation between the coil 4 and the stator core 1 can be manufactured, so that the manufacturing cost can be reduced. .

It is a process figure which shows the manufacturing process of a stator core and prepares a stator core, insulating paper, and a coil. It is a process figure which shows the manufacturing process of a stator core and inserts a coil in a coil accommodation groove part. It is a process figure which shows the manufacturing process of a stator core and prepares a division | segmentation stator core. It is a process figure which shows the manufacturing process of a stator core and arrange | positions a split stator core in the upper end surface and lower end surface of a cylindrical stator core. It is a process figure which shows the manufacturing process of a stator core, and shows the state which has arrange | positioned the division | segmentation stator core in the upper end surface of a stator core. It is a process figure which shows the manufacturing process of a stator core and inserts and fixes a stator core in a motor case. It is a process figure which shows the manufacturing process of a stator core and presses and fixes a divided stator core to a stator core with a ring-shaped fixing member. It is a perspective view which shows the other example of a division | segmentation stator core.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Stator core 2 ... Coil accommodation groove part 3 ... Insulation paper 4 ... Coil 4A, 4B ... Coil end part 5 ... Steel plate 8 ... Divided stator core 10 ... Core part 11 ... Insulation cover 12 ... Motor case 14 ... Ring-shaped fixing member 14A ... Core Holding part

Claims (6)

A step of inserting an annular coil into the coil housing groove after disposing insulating paper in each coil housing groove formed in the cylindrical stator core;
Forming both end portions of the coil projecting outward from both end portions of the coil receiving groove portion into a predetermined shape to form a coil end portion, and forming a gap portion between the both end portions of the coil and the end surface of the stator core; When,
Each of the divided stator cores, which are divided into a plurality of parts whose planar shapes when combined are substantially the same as the upper end surface shape and the lower end surface shape of the stator core, are inserted into the gap portions formed in the coil end portions. Thus, the step of arranging on the upper end surface and the lower end surface of the stator core,
And a step of inserting and fixing the stator core, to which the divided stator core is attached, in a motor case. It is a manufacturing method of the stator core according to claim 1,
A method of manufacturing a stator core, comprising: a step of pressing and fixing the divided stator cores arranged on the upper end surface and the lower end surface of the stator core against the stator core with a ring-shaped fixing member fixed to the motor case. A cylindrical stator core having a plurality of coil receiving grooves formed on the inner surface;
Insulating paper disposed in each coil housing groove,
A coil end portion that is inserted and disposed in the coil receiving groove portion from above the insulating paper, and a portion protruding outward from the coil receiving groove portion is formed into a predetermined shape, and the coil end portion and the stator core An annular coil with a gap in between,
A divided stator core that is divided into a plurality of planar shapes that are substantially the same as the shape of the upper end surface and the lower end surface of the stator core when combined,
A motor case for inserting and fixing the stator core to which the divided stator core is attached;
Each of the divided stator cores is disposed on an upper end surface and a lower end surface of the stator core so as to be inserted into the gap portion formed in the coil end portion. The stator core according to claim 3, wherein
A stator core comprising: a ring-shaped fixing member that presses and fixes the divided stator cores disposed on the upper end surface and the lower end surface of the stator core against the stator core. The stator core according to claim 3 or 4, wherein
Like the stator core, the split stator core includes a core portion formed by laminating a plurality of thin steel plates, and an insulating cover attached to the core portion so as to cover at least a portion in contact with the coil. A featured stator core. The stator core according to claim 5, wherein
The stator core is formed by coating the core portion with an insulating resin.

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