JP2008306816A - Manufacturing method of divided stator, manufacturing method of stator, and manufacturing method of motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a divided stator which comprises a process for reducing a gap between electric wires by pressing an electric wire layer formed by winding the electric wires to a core in a core direction, and is suppressed in a problem such as the displacement of the electric wires, and a slide between the electric wires which occur at the pressing. <P>SOLUTION: The manufacturing method of the divided stator comprises: a winding step for winding on the core an insulation-coated electric wire having a conductive wire and an insulation layer which coats the conductive wire layer, and forming the electric wire layer; and a compression process which presses the electric wire layer to the core direction. The manufacturing method of the divided stator is characterized in that the pressing is performed while a temperature is kept within the same range after the insulation-coated electric wire is heated to a temperature range in which a temperature is not lower than 160°C, and lower than a melting point of the insulating layer. There are also provided a manufacturing method of a stator which uses the divided stator obtained by the manufacturing method of the divided stator, and a manufacturing method of a motor which uses the stator obtained by the manufacturing method of the stator. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a split stator that constitutes a stator of a motor or a generator. The present invention further relates to a stator manufacturing method characterized by using this divided stator, and a motor manufacturing method characterized by using this stator.

  In order to increase the output of motors and generators, i.e., rotating electrical machines, as a stator constituting the rotating electrical machines, a yoke, a collar, a core composed of teeth connecting the yoke and the collar, and an insulating material (insulator) covering the core In addition, a stator in which a split stator composed of a wire layer (solenoid part) formed by winding an electric wire in multiple layers on a tooth via an insulator is used in an annular shape with a yoke as an outer peripheral side is widely used. It has been. By using this stator, a high output can be obtained and the winding of the electric wire in the manufacture of the stator can be facilitated. And the method of aligning and winding an electric wire is proposed in Unexamined-Japanese-Patent No. 7-183152, Unexamined-Japanese-Patent No. 2003-333882, etc.

In order to further increase the output, it is desirable to reduce the gap between the wound wires. For this reason, in manufacturing the split stator, a method is also considered in which an electric wire is wound on a core to form an electric wire layer, and then pressed from the outside toward the core to be compressed. The cross section of the electric wire wound by this press is deformed, and the gap between the electric wires is reduced.
JP-A-7-183152 JP 2003-333882 A

  However, in this method, when the stress applied during the pressing is large, fault displacement between the wires constituting the wire layer (shift between the wires), friction between the wires, deterioration of magnetic properties due to deformation of the core, etc. The problem is likely to occur. When the electric wire is displaced, the gap between the electric wires becomes larger, and the rubbing between the electric wires may lead to destruction of the insulating layer.

  FIG. 5 is a schematic cross-sectional view for more specifically explaining the deviation of the electric wire, which is an example of the above problem. FIG. 5A is a cross-sectional view of the electric wire 21 wound around the core 5. The electric wire 21 is an enameled wire including a conductor wire 23 made of copper or the like and an insulating layer 24 covering the outer periphery thereof. Polyamideimide, polyimide, or the like is used as the material of the insulating layer 24, but the insulating layers made of these are easily slidable with each other. FIG. 5B is a cross-sectional view of the core 5 taken along a plane in the direction in which the divided stators are arranged, and is a conceptual cross-sectional view showing only one side from the central axis. Shows a state where is wound.

  In order to further reduce the gap between the electric wires, the electric wire layer is pressed in the direction of the arrow P (the direction of the core 5) in the drawing. Since the insulating layers 24 are slidable with each other, displacement and rubbing are likely to occur between the wires when the stress of the press is large. FIG.5 (c) is a conceptual sectional drawing which shows the mode of the shift | offset | difference of the electric wire after a press in the core 5 represented by FIG.5 (b). In the figure, it is shown that a deviation between the electric wires occurs in a portion L surrounded by an ellipse.

  An object of the present invention is to solve the problems in the production of the split stator described above. That is, a method of manufacturing a split stator including a step of pressing an electric wire layer formed by winding an electric wire around a core in a core direction to reduce a gap between the electric wires. It is an object of the present invention to provide a method in which problems such as slippage are suppressed.

  As a result of the study, the present inventors have found that the above-mentioned problem can be achieved by heating the electric wire layer to a predetermined temperature or higher in the compression step, and have completed the present invention having the following configuration.

The present invention includes a winding process in which a conductor wire and an insulation-coated electric wire having an insulating layer covering the conductor wire are wound on a core to form a wire layer, and a compression process in which the wire layer is pressed in the core direction. A method of manufacturing a split stator comprising:
The method of manufacturing a split stator, wherein the pressing is performed while heating the insulation-coated electric wire to a temperature range of 160 ° C. or higher and lower than the melting point of the insulating layer, and maintaining the temperature within the same range (Claim 1). ).

  This manufacturing method has the conventional split stator as described above in that it includes a winding step of winding an electric wire on a core to form an electric wire layer, and a compression step of subsequently pressing the electric wire layer in the core direction. This is the same as the manufacturing method. The wound wire is the same as the conventional split stator manufacturing method in that it is composed of a conductor wire and an insulating layer covering the conductor wire. For example, it is the same as the wire shown in FIG. A simple electric wire is used.

  In the manufacturing method of the present invention, after the winding step, the electric wire layer is heated to a temperature of 160 ° C. or higher and lower than the melting point of the insulating layer, and the electric wire layer is pressed in the core direction at a temperature of 160 ° C. or higher and lower than the melting point of the insulating layer. The compression process is performed.

  When the electric wire layer is heated to a temperature of 160 ° C. or higher, the electric conductor of the electric wire becomes soft, and the cross section of the electric wire can be deformed with a smaller stress in the press, and the gap between the electric wires can be reduced. As a result of being able to perform the press with a smaller stress, problems such as a shift of the electric wire, slippage between the electric wires, and deformation of the core that occur during pressing can be suppressed.

  In order to achieve the above-mentioned problem, the heating temperature needs to be 160 ° C. or higher. In order to make the conductor softer and reduce the stress required for pressing, it is preferable that the heating temperature be higher. However, if the heating temperature is equal to or higher than the melting point of the insulating layer, the insulating layer is broken and deformed during pressing, and dielectric breakdown tends to occur. Therefore, the heating temperature must be lower than the melting point of the insulating layer. . Here, the melting point of the insulating layer means the softening start temperature of the insulating layer. The softening start temperature can be measured using differential scanning calorimetry (DSC).

  In order to make the conductor of the electric wire softer and reliably prevent dielectric breakdown, the insulated coated electric wire should be at least 60 ° C. lower than the melting point of the insulating layer (and 160 ° C. or higher) and 10 ° C. above the melting point of the insulating layer. After heating to a range below a low temperature, it is preferable to press while keeping the temperature within the same range (Claim 2). For example, in the case of an insulation-coated electric wire having an insulating layer made of polyamideimide having a melting point near 260 ° C., that is, an enameled wire, heating at about 200 to 250 ° C. is preferable.

  The pressing method in the compression step can be performed in the same manner as conventionally performed in the method of manufacturing a split stator for a rotating electrical machine, and can be performed using, for example, a flat punch. The press reduces the gap between the electric wires and the gap between the electric wires and the core (insulator).

  The present invention further provides, as a preferred embodiment thereof, a method of manufacturing a split stator, wherein the core has a side surface parallel to a side surface of the outer periphery of the split stator. As will be described later, the divided stators are arranged in an annular shape to form a stator. However, in order to obtain a high output, it is necessary to arrange the divided stators without gaps. It is necessary to make the sectional shape of the split stator into a trapezoidal shape that is large on the yoke side and small on the collar side. Therefore, both side surfaces (side surfaces of the outer periphery of the divided stator) on the arrangement direction side of the divided stator are inclined with respect to each other. For example, as shown in FIG. 5B, the divided stator is divided into two equal parts. Each of the side surfaces D on the outer periphery of the divided stator is inclined with respect to the central axis surface C.

  Therefore, as in the example shown in FIG. 5B, when the side surface of the core 5 on the direction side where the divided stators are arranged is parallel to the central axis surface C, the wires are stepped on the outermost periphery of the wire layer. As a result, a partial stress concentration occurs during pressing, and a deviation or the like is likely to occur. As shown in FIG. 2, if the side surface B of the core is parallel to the side surface D of the outer periphery of the split stator on the direction side in which the split stator is arranged, the wires need to be stepped even at the outermost periphery of the wire layer. No, it is possible to further suppress the occurrence of stress concentration and deviation during pressing.

  According to the present invention, as a further preferred aspect of the method for manufacturing a split stator according to claim 3, the parallel side surface has a step having a height substantially equal to an integral multiple of the thickness of the electric wire layer. A manufacturing method is provided (claim 4). If the core has a side surface parallel to the outer peripheral side surface of the divided stator, the cross-sectional area of the core decreases from the yoke side toward the collar side, and as a result, the magnetic characteristics deteriorate. Therefore, as shown in FIG. 1, by providing a step in the core, the variation in the cross-sectional area of the core from the yoke side toward the collar side can be reduced, and as a result, the deterioration of the magnetic characteristics is suppressed. be able to.

  The height of the step is a height substantially equal to an integral multiple of the thickness of the wire layer. With this height, the electric wire layer is not displaced even at the stepped portion, and the electric wire can be wound closely and aligned.

  The present invention also provides a method for manufacturing a stator, wherein a plurality of divided stators manufactured by the method for manufacturing a split stator according to the present invention are assembled in an annular shape adjacent to each other. . According to this stator manufacturing method, the winding and pressing of the electric wire is performed for each divided stator, so that the winding of the electric wire (coil formation) is easy and the press for reducing the gap between the electric wires. Can also be done easily.

  The present invention further provides a method for manufacturing a motor using a stator obtained by the method for manufacturing a stator. The stator is formed by annularly arranging divided stators in which the gaps between the wires are reduced. By using this, a high output motor can be obtained without increasing the size.

  According to the method for manufacturing a split stator of the present invention, it is possible to manufacture a split stator in which the gap between the electric wires is reduced while suppressing the deviation and rubbing between the electric wires and the occurrence of deformation of the core. According to the stator manufacturing method of the present invention, winding of the electric wire is easy, and pressing for reducing the gap between the electric wires can be easily performed. By using the stator manufactured by this method, a high output motor can be easily obtained.

  Next, embodiments of the present invention will be described more specifically with reference to the drawings. However, the scope of the present invention is not limited to these embodiments.

  FIG. 4B shows the shape of the core 5 constituting the split stator of the present invention. The core 5 includes a yoke 11, a tooth 12 and a collar 13. As the core, for example, a core made of a magnetic material such as iron can be used. Usually, the core is covered with an insulator for ensuring insulation from the electric wire.

  A typical example of the insulator material is polyphenylene sulfide (PPS), but polyethylene, polyimide, polyetheretherketone (PEEK), liquid crystal polymer (LCP), and the like are also used. The insulator may be provided with guide grooves (not shown) to facilitate the winding of the windings.

  The electric wire 21 whose cross section is represented in FIG. 5A is wound on an insulator that covers the teeth 12 to form an electric wire layer. As shown in FIG. 4B, the yoke 11 is longer than the collar 13. The electric wire 21 is a round wire having a circular cross section, but as the electric wire, a polygonal wire such as a flat wire can be used in addition to the round wire. Moreover, the multiple wire | winding which winds several coil | windings simultaneously may be sufficient.

  As described above, FIG. 5B is a cross-sectional view when the core 5 after the electric wire 21 is wound and the electric wire layer is formed is cut along a plane in the direction in which the divided stators are arranged. FIG. 3 is a conceptual cross-sectional view showing only one side from a central axis plane C. In FIG.5 (b), 14 represents an insulator and 17 represents the flat punch used for a press. P indicates the direction of pressing, and after the electric wire 21 is wound and the electric wire layer is formed, the electric wire layer is shown pressed in the P direction by the flat punch 17.

  As shown in FIG. 5 (b), the side surface (side surface of the outer periphery of the divided stator) D on the arrangement direction side of the divided stator is inclined with respect to the central axis plane C that bisects the divided stator. Yes. In the core of the split stator shown in FIG. 5B, the side surface B of the core is parallel to the central axis surface C, and is therefore inclined with respect to the side surface D of the split stator. As a result, if the electric wires 21 are closely aligned with each other and are to be wound in the maximum range where they do not interfere with the adjacent divided stator, the electric wires must be wound in a stepped manner at the outermost periphery of the electric wire layer. A dead space 7 is generated, and stress concentration is likely to occur during pressing.

  FIG. 2 is also a cross-sectional view when the core 5 after the electric wire 21 is wound and the electric wire layer is formed is cut along a plane in the direction in which the divided stators are arranged, similarly to FIG. FIG. 6 is a conceptual cross-sectional view showing only one side from the central axis plane C. However, in the core 5 of the split stator shown in FIG. 2, the side surface B of the core 5 is parallel to the side surface D of the split stator, and as a result, the outermost periphery of the wire layer is also parallel to the side surface D of the split stator. No dead space occurs. Therefore, even when the flat punch 17 is pressed in the P direction, stress concentration hardly occurs.

  In the core 5 of the split stator shown in FIG. 2, the cross-sectional area becomes smaller as it goes from the yoke 11 side to the collar 13 side, which may cause a problem that the magnetic characteristics of the stator are deteriorated. In the core 5 of the split stator shown in FIG. 1, the side surface B of the core 5 is parallel to the side surface D of the split stator and has a step 8 having a height substantially equal to the thickness of one layer of the electric wire layer. . As a result, the fluctuation of the cross-sectional area of the core from the yoke 11 side toward the collar 13 side can be reduced, and the deterioration of the magnetic characteristics can be suppressed. Moreover, since the height of the level | step difference 8 is substantially equal to the thickness of 1 layer of an electric wire layer, an alignment winding can also be made easy. The step 8 is preferably arranged so that the distance between the central axis surface C and the side surface B of the core 5 does not vary more than the height of the step in the length direction of the teeth 12.

  Next, the manufacturing method of the divided stator according to the present invention will be specifically described based on the examples of FIGS. First, the electric wire 21 is wound closely and in parallel on the insulator 14 covering the teeth 12 of the core 5, and the outer peripheral surface (adjacent divided stator side) is a boundary surface (divided) with the adjacent divided stator. An electric wire layer exceeding a surface substantially coincident with the side surface D of the stator is formed (winding step). 1 and 2 show a state in which the electric wire layer is formed.

  After the electric wire layer is formed, it is pressed in the direction of the core 5 (the direction of the teeth 12) until the outer peripheral surface is in the side surface D of the split stator. 1 and 2 show a compression process in which the electric wire layer is pressed in the direction of the arrow P in the figure by the flat punch 17.

  In the present invention, after the winding step, the electric wire layer is heated to a temperature of 160 ° C. or higher and lower than the melting point of the insulating layer. Although it does not specifically limit as a heating method, The method of blowing the warm air to an electric wire layer, energizing the electric wire 21, and heating with a Joule heat etc. is employable.

  The pressing by the flat punch 17 is performed after this heating, and the temperature at the time of pressing is also maintained at a temperature of 160 ° C. or higher and lower than the melting point of the insulating layer. As a result, the conductor wire 23 of the electric wire 21 becomes soft, and the cross section of the electric wire 21 can be deformed with a small press stress, and the gap between the electric wires 21 can be reduced. As a result of being able to perform the press with a smaller stress, problems such as a shift of the electric wire, slippage between the electric wires, and deformation of the core that occur during pressing can be suppressed.

  FIG. 3 is a schematic cross-sectional view showing a state after the divided stator in the example of FIG. 1 is pressed as described above. By pressing, the outer peripheral surface of the electric wire layer becomes a position that substantially coincides with the side surface D of the split stator. By pressing in this way, when the stator is formed, interference with the adjacent divided stator can be avoided.

  As shown in FIG. 3, the cross-sectional shape of the electric wire 21 is a polygon (hexagonal shape) except for the portion in contact with the core 5 and the surface portion, and there is almost no gap between the electric wires 21 before pressurization. It has disappeared. As a result, the so-called space factor is improved, and a high output motor can be manufactured without increasing the size.

  FIG. 4A is a conceptual diagram showing how the stator is formed by arranging the divided stator of the present invention in an annular shape around the center O. FIG. In order to make the illustration easy to understand, the split stator shows only one of them, and the stator having an annular cross section is shown by a dotted line. The split stator A includes a core 5 and an electric wire layer 6. The electric wire layer 6 is shaded, and illustration of individual electric wires and insulators is omitted.

  Such a stator can be obtained by arranging divided stators circumferentially as shown in the figure and fixing them together. As a method of fixing each other, a method of fixing adjacent split stators with a fixing tool, a method of fixing each other by a hook provided on a yoke part or a collar part of the split stator, and each split stator on a ring-shaped member. Although the method of fixing etc. is mentioned, these are not illustrated.

It is a schematic cross section which shows a mode that the electric wire layer of a division | segmentation stator is pressed. It is a schematic cross section which shows a mode that the electric wire layer of a division | segmentation stator is pressed. It is a schematic cross section which shows a mode after the electric wire layer of a split stator is pressed. In a stator, it is sectional drawing which shows a mode that the division | segmentation stator is arrange | positioned, and a perspective view which shows the core of a division | segmentation stator. It is sectional drawing of the electric wire which forms a division | segmentation stator, and a schematic cross section which shows a mode that the electric wire layer of a division | segmentation stator is pressed.

Explanation of symbols

5 Core 6 Electric wire layer 8 Step 11 Yoke 12 Teeth 13 Brim 14 Insulator 17 Flat punch 21 Electric wire 23 Conductor wire 24 Insulating layer B: Core side surface C: Central axis surface D: Split stator side surface P: Direction to be pressed

Claims (6)

A split stator having a winding step of forming an electric wire layer by winding an insulating coated electric wire having a conductor wire and an insulating layer covering the conductor wire on the core, and a compression step of pressing the electric wire layer in the core direction A manufacturing method comprising:
A method of manufacturing a split stator, wherein the pressing is performed while heating the insulated coated electric wire to a temperature range of 160 ° C. or higher and lower than the melting point of the insulating layer, and maintaining the temperature within the same range.   2. The split stator according to claim 1, wherein the pressing is performed while heating the insulation-coated electric wire to a temperature range lower by 60 to 10 ° C. than the melting point of the insulating layer, and maintaining the temperature within the same range. Production method.   The method of manufacturing a split stator according to claim 1, wherein the core has a side surface parallel to a side surface of the outer periphery of the split stator.   The method of manufacturing a split stator according to claim 3, wherein the parallel side surface has a step having a height substantially equal to an integral multiple of the thickness of the electric wire layer.   A stator manufacturing method, wherein a plurality of split stators manufactured by the method of manufacturing a split stator according to any one of claims 1 to 4 are assembled in an annular shape adjacent to each other.   A method for manufacturing a motor, comprising using the stator manufactured by the method for manufacturing a stator according to claim 5.

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