JP2015201958A - Stator of rotary electric machine and manufacturing method of stator of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator of a rotary electric machine capable of preventing tight winding on an iron core from being generated while winding a coil thereon while allowing an insulator to firmly adhere onto the iron core.SOLUTION: A gap S in an end part 5d between a load side insulator 5a and anti-load side insulator 5b which are divided into two parts in a shaft longitudinal direction of the iron core 4 is filled with an insulation varnish 9. A filling holes 5c in a load side insulator 5a and an anti-load side insulator 5b and core piece 40 of the iron core 4 corresponding to the gap S are also filled with the insulation varnish 9. With this, ground insulation characteristics of the coil 6 are improved.

Description

  The present invention relates to a stator of a rotating electrical machine and a method for manufacturing the stator of the rotating electrical machine, and more particularly to an insulation configuration between a stator core and a stator coil of the rotating electrical machine and a manufacturing method thereof.

  Conventionally, in a stator coil of a rotating electrical machine, a stator coil is wound around an insulator composed of a load-side insulator and an anti-load-side insulator around a tooth portion of a laminated stator core in an insulating structure having split-type insulators. In this case, a convex portion is provided on the joint surface of one of the cylindrical body portions of the load side insulator or the anti-load side insulator, and a concave portion that fits the convex portion is formed on the joint surface of the other cylindrical body portion. The provided technique is shown (for example, refer patent document 1).

JP 11-41849 A

  However, the technique disclosed in Patent Document 1 is provided with a convex portion on one cylindrical body portion of the load-side insulator or the anti-load-side insulator and a concave portion on the other side. In addition to ensuring strength, it is also necessary to increase the wall thickness in order to fill the concavo-convex portion with resin when the insulator is resin-molded. When the wall thickness is increased in this way, the winding space is reduced, and it is necessary to reduce the conductor diameter in order to secure the required coil winding. As a result, there is a problem in that copper loss increases and efficiency decreases. is there. Further, the manufacturing cost of the insulator increases due to the uneven structure. Furthermore, since the insulator is not fixed to the stator core, there is a problem that a shift occurs in the conveying process and the productivity is hindered.

  The present invention has been made to solve the above-described problems. An insulator of a rotating electrical machine having a simple stator structure and a solid stator structure in which a resin is filled in a gap between the insulator and the iron core. It is an object of the present invention to provide a method of manufacturing a stator and a stator of the rotating electric machine.

The first invention is
In a stator of a rotating electrical machine in which a magnetic pole having a coil wound through a resin molded product insulator mounted so as to surround an iron core formed by stacking core pieces is attached to a frame, the insulator is an iron core The load-side insulator and the anti-load-side insulator are divided into two in the longitudinal direction of the shaft, and the load-side insulator and the anti-load-side insulator are provided with a filling hole with a predetermined distance at each facing end. In addition, the load-side insulator and the anti-load-side insulator are fixed to the iron core by attaching the insulating varnish to the filling hole and the gap so as to form a gap between the opposite ends. In addition, the core piece corresponding to the filling hole and the gap is fixed by an insulating varnish.

A second invention is a method of manufacturing a stator for a rotating electrical machine, characterized by having the following steps.
Step 1. Step 2. Laminate core pieces made by punching electrical steel sheets into iron cores Step 2. 2. Applying an insulating varnish to the iron core, and attaching the load side insulator and the anti-load side insulator of the resin molded product to the iron core. Insulation between the core pieces of the iron core corresponding to the gap and the filling hole by filling the load-side insulator, the filling hole provided in the anti-load-side insulator, and the gap where the load-side insulator and the anti-load-side insulator face each other Filling the varnish, curing the insulating varnish, fixing the load-side insulator and the anti-load-side insulator to the iron core and fixing between the core pieces; Step 5: Winding a coil around an iron core fitted with a load-side insulator and an anti-load-side insulator to form magnetic poles Attaching the magnetic pole to the frame

  Since the stator of the rotating electrical machine according to the first invention adopts the above-described configuration, the rigidity of the iron core is improved and the adhesion of the load-side insulator and the anti-load-side insulator to the iron core is improved. Further, it is possible to prevent the occurrence of tightening of the iron core due to the coil tension at the time of coil winding, and it is possible to prevent the deterioration of the ground insulation of the coil due to the occurrence of the tightening of the iron core.

  In addition, since the stator of the rotating electrical machine according to the second invention includes the manufacturing steps as described above, in addition to the same effects as in the first invention, the load-side insulator and the anti-load are conveyed during the transportation of the manufacturing process. The side insulator can be prevented from being displaced or detached from the iron core, and the productivity can be improved.

FIG. 3 is a diagram showing a stator structure of a rotating electrical machine according to the first embodiment. FIG. 3 is a diagram illustrating a magnetic pole according to the first embodiment. It is the figure which attached the load side insulator and the anti-load side insulator to the iron core by Embodiment 1. FIG. It is a figure which shows the filling state of the insulating varnish by Embodiment 1. FIG. It is a figure which shows the filling state to the clearance gap S of the insulating varnish by Embodiment 1. FIG. It is a figure explaining generation | occurrence | production of winding tightening of an iron core by the coil tension in a coil winding process. It is a figure which shows the edge part shape of the load side insulator by Embodiment 2, and the filling state of the insulating varnish of an anti-load side insulator. FIG. 6 is a diagram illustrating a magnetic pole according to a third embodiment.

Embodiment 1 FIG.
Embodiment 1 of the present invention will be described below with reference to the drawings. FIG. 1 shows a stator 1 of a rotating electrical machine, FIG. 1 (a) is a front view, and FIG. 1 (b) is a cross-sectional view taken along line XX of FIG. 1 (a). The stator 1 is provided with a plurality of magnetic poles 3 in a cylindrical frame 2. 2 is a diagram showing the magnetic pole 3 for one pole, FIG. 2 (a) is a plan view, and FIG. 2 (b) is a central sectional view of FIG. 2 (a). 3 is a view showing the iron core 4 and the insulator 5 shown in FIG. 2 before coil winding, FIG. 3 (a) is a plan view, and FIG. 3 (b) is a side sectional view of FIG. 3 (a). . As shown in FIGS. 1, 2, and 3, the magnetic pole 3 is wound on an iron core 4 in which a core piece 40 punched out of a thin electromagnetic steel sheet is laminated, and an insulator 5 of a resin molded product provided on the iron core 4. The coil 6 is constituted. As can be seen from FIG. 3 (c), the insulator 5 has a U-shaped cross section and is mounted on the iron core 4. The load side (output side of the rotating electrical machine) insulator 5a of the iron core 4 and the anti-load side insulator 5b. It consists of and. The insulator 5 is thus divided into two in the axial direction of the iron core 4 because the tooth portion 41 shown in FIG. 3 is larger than the width of the iron core 4. The sum of the axial lengths of the load-side insulator 5 a and the anti-load-side insulator 5 b is shorter than the length of the iron core 4. This is to absorb variations in the thickness of the iron core 4 due to variations in the thickness of the electromagnetic steel sheets when the core pieces 40 are stacked, pressure variations during stacking, and the like, and the load-side insulator 5a and the anti-load-side insulator 5b. This is because the workability at the time of mounting to the iron core 4 is not hindered. As a result, a gap S is formed as shown in FIG. The load-side insulator 5a and the anti-load-side insulator 5b have a winding frame function that allows the coil 6 to be wound around a predetermined position, and a ground insulation function of the coil 6 with respect to the iron core 4. A slit-shaped filling hole 5c is provided at a predetermined distance L from 5d. Although this distance L is set by the size of the iron core 4, it is desirable that the distance L be close to the end 5d. The filling hole 5c is not limited to a slit shape, but may be a circle or an ellipse. FIG. 3C is a conceptual diagram showing the filling hole 5c. In FIG. 3C, the flange 5f is omitted.

  As shown in FIG. 8 of the third embodiment to be described later, the stator 1 has a plurality of iron cores 4 continuously arranged, and after winding the coil 6, it is shrink-fitted or press-fitted into the frame 2 as shown in FIG. By being tightened, it is connected. As shown in FIG. 3, the core piece 40 forming the iron core 4 includes a back yoke portion 42 provided in the circumferential direction of the stator 1, and a teeth portion 41 projecting radially from the back yoke portion 42. A caulking portion 43 is provided in the portion 42. The caulking part 43 forms an uneven part by punching in the core piece 40, and the convex part and the concave part are associated with each other to form a core 4. The caulking portion 43 may be formed on the tooth portion 41. Next, the insulating structure of the coil 6 composed of the insulator 5 and the insulating varnish 9 will be described with reference to FIG. FIG. 4A shows the concept of injecting the insulating varnish 9 from the dispenser 8, and the dispenser 8 is driven by a robot or the like. After the insulating varnish 9 described later is applied to the surface of the iron core 4 and the insulator 5 is mounted, the load-side insulator 5a and the anti-load-side insulator 5b are filled with the gap S formed at the end 5d and the filling as shown in FIG. The hole 5c is fixed to the load-side insulator 5a, the anti-load-side insulator 5b, and the iron core 4 by filling the hole 5c with an insulating varnish 9 such as an epoxy type and curing it. The insulating varnish 9 may be cured by heating using, for example, a thermosetting resin or UV irradiation using a UV curable resin. Since such an insulating structure is employed, as shown in FIG. 5, the fixing property between the iron core 4, the load-side insulator 5a, and the anti-load-side insulator 5b is improved, and the core piece 40 is formed from the gap S and the filling hole 5c. The insulating varnish 9 penetrates into the gap between the layers, and the rigidity of the iron core 4 is improved. Therefore, in the winding work process of the coil 6, the iron core 4 can prevent the occurrence of tightening due to the coil winding tension, and there is an effect that there is no concern that the ground insulation of the coil 6 is lowered due to the occurrence of the tightening. Here, FIG. 6 illustrates a state in which winding of the iron core 4 occurs. That is, the width W1 of the iron core 4 on the back yoke portion 42 side is larger than the width W2 of the iron core 4 on the tooth portion 41 side. Further, since the insulating varnish 9 is filled in the gap S, the ground insulation of the coil 6 can be prevented from being lowered without the coil 6 contacting the iron core 4. Furthermore, since the load-side insulator 5a and the anti-load-side insulator 5b are fixed to the iron core 4, it is possible to suppress the occurrence of deviation from the iron core 4 in the conveying process during manufacture, and to improve productivity.

Embodiment 2. FIG.
In the second embodiment, the end portions 5d of the load-side insulator 5a and the anti-load-side insulator 5b of the first embodiment are tapered 5e as shown in FIG. The taper shape 5e prevents the insulating varnish 9 from being cured in a mountain shape in the gap S due to the surface tension, and as a result, the insulation performance can be prevented from being lowered due to the local rise of the coil 6. In addition, the winding workability of the coil 6 can be improved.

Embodiment 3 FIG.
In the first embodiment and the second embodiment described above, the case where the magnetic pole 3 is a single pole has been illustrated and described. However, in this third embodiment, as shown in FIG. The iron core 4 is rotatably connected by a rotation connecting portion 45. By applying to the stator 1 having such a structure, the magnetic pole 3 can be handled as one body, and workability such as conveyance and assembly can be improved, and the iron core 4 can be expanded to be filled with the insulating varnish 9. Also, the filling workability is improved. Although filling is performed using a plurality of dispensers 8 in FIG. 8, filling may be performed for each iron core 4 with one dispenser 8.

Embodiment 4 FIG.
In this Embodiment 4, the manufacturing method of the stator 1 of Embodiment 1- Embodiment 3 mentioned above is demonstrated. This manufacturing method is also described for the case where the magnetic pole 3 is a single pole, but it may be the case where the plurality of iron cores 4 are connected. First, a thin electromagnetic steel sheet is punched out to produce the core piece 40 shown in FIG. 3A, and the convex and concave portions of the caulking portion 43 of the core piece 40 are engaged and laminated, and an iron core having a predetermined core length. 4 is created. Next, an insulating varnish 9 is applied to the iron core 4, and the load-side insulator 5a and the anti-load-side insulator 5b of the resin molded product are mounted on the iron core 4 as shown in FIG. The filling hole 5c of the side insulator 5b and the gap S formed so that the end portion 5d of the load-side insulator 5a and the end portion 5d of the anti-load-side insulator 5b face each other are filled with the insulating varnish 9, and the filling hole 5c and the core varnish 40 of the iron core 4 corresponding to the gap S are filled with the insulating varnish 9, and then the insulating varnish 9 is heated and cured, whereby the load-side insulator 5a and the anti-load-side insulator 5b are formed on the iron core 4. , And between the core pieces 40 of the iron core 4, the load-side insulator 5 a and the anti-load-side insulator are fixed. The b as winding frame, creating a pole 3 and winding the coil 6. Since the coil 6 is wound in the above-described process, the iron core 4 is strengthened, and the iron core 4 as shown in FIG. 6 is tightened by the tension at the time of winding of the coil 6, that is, the iron core on the teeth portion 41 side. 4 is less than the width W1 of the iron core 4 on the back yoke portion 42 side, and the insulating varnish 9 is filled in the gap S, so that the coil 6 is prevented from coming into contact with the iron core 4. As a result, the ground insulation of the coil 6 does not deteriorate. That is, in the past, the insulating varnish 9 was impregnated after the coil 6 was wound, but this is not an effective means for the grounding phenomenon of the coil 6 that occurs when the coil 6 is wound as described above. By adopting the structure method of aspect 4, excellent ground insulation can be ensured. The magnetic pole 3 formed in this way is attached to the frame 2 to form a stator 1 as shown in FIG. Thereafter, vacuum impregnation of the varnish is performed to further improve the insulating property, heat resistance, and the like of the coil 6, and the stator 1 of the rotating electrical machine having stable performance is obtained.

  It should be noted that within the scope of the present invention, the embodiments can be freely combined, or the embodiments can be appropriately modified or omitted.

1 stator, 2 frames, 3 magnetic poles, 4 iron cores, 5 insulators,
5a Load-side insulator, 5b Anti-load-side insulator, 5c Filling hole,
5d end, 5e taper, 9 insulating varnish, 40 core pieces, S gap.

Claims (3)

In a stator of a rotating electrical machine in which a magnetic pole including a coil wound through an insulator of a resin molded product attached so as to surround an iron core formed by stacking core pieces is attached to a frame, the insulator is The load-side insulator divided into two in the axial direction of the iron core and an anti-load-side insulator, and the load-side insulator and the anti-load-side insulator have a predetermined distance at each facing end. A filling hole is provided, and is attached to the iron core so as to form a gap between the opposed end portions, and the filling hole and the gap are filled with an insulating varnish, whereby the load-side insulator and the An anti-load-side insulator is fixed to the iron core, and between the core pieces corresponding to the filling hole and the gap The stator of the rotating electric machine, characterized in that it is secured by the insulating varnish. The manufacturing method of the stator of the rotary electric machine characterized by having the following step.
Step 1. Step 2. Laminate core pieces made by punching electrical steel sheets into iron cores Step 2. 2. Applying an insulating varnish to the iron core, and mounting the load-side insulator and the anti-load-side insulator of the resin molded product to the iron core. The load side insulator, the filling hole provided in the anti-load side insulator, and the gap corresponding to the gap and the filling hole by filling the gap facing the load side insulator and the anti-load side insulator with insulating varnish. Filling the insulating varnish between the core pieces of the iron core, curing the insulating varnish, fixing the load-side insulator and the anti-load-side insulator to the iron core and fixing between the core pieces; 4. A coil is wound around an iron core on which the load-side insulator and the anti-load-side insulator are mounted. Attaching the magnetic pole to the frame The stator of the rotating electrical machine according to claim 1, wherein the end portions of the load-side insulator and the anti-load-side insulator are tapered.

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