JP2016034228A - Axial gap type electrical rotating machines and manufacturing method of stator core for axial gap type electrical rotating machines - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of stator core for axial gap type electrical rotating machines and a stator core for axial gap type electrical rotating machines capable of improving the utilization ratio of electrical steel by reducing the ratio of a punch-out material relative to the material part used as a back yoke portion and a tooth portion resulting in a reduction of production cost.SOLUTION: A manufacturing method of stator core for axial gap type electrical rotating machines, includes: a core piece punch-out step in which a first core piece 11A and a second core piece 11B are punched out from a sash-like magnetic material 10 which extends in a length direction with a certain width in a state that the first core piece 11A is reversely disposed on the second core piece 11B so that the tooth portions 11b of the first core piece 11A are positioned between the tooth portions 11b of the second core piece 11B, the core pieces 11B of them being arranged parallel to each other in a row in a length direction of a core back portion 11a.SELECTED DRAWING: Figure 7

Description

  The present invention relates to an axial gap type rotating electrical machine in which a surface perpendicular to a rotating shaft serves as a torque transmission surface, and a method for manufacturing a stator core for an axial gap type rotating electrical machine.

  In radial gap type rotating electrical machines, the cylindrical surface with the rotation axis as the central axis is the torque transmission surface, and the magnetic flux flows in a two-dimensional cross section perpendicular to the rotation axis. The generation of eddy currents was suppressed by using a stator core that was used, and loss due to eddy currents was reduced. On the other hand, in the axial gap type rotating electrical machine in which the surface perpendicular to the rotation axis is the torque transmission surface, the magnetic flux flows in the axial direction through the teeth, and therefore a stator configured by laminating thin electromagnetic steel sheets in the axial direction. When an iron core is used, eddy current is generated, and loss due to eddy current is remarkably increased.

  In view of such circumstances, the slot opening is punched out of the strip of electromagnetic steel sheet to form the teeth portion and the core back portion, and the strip formed with the teeth portion and the core back portion is concentric with the disk member. There has been proposed a wound iron core produced by winding in a plane. This wound iron core is constructed by laminating strips made of electromagnetic steel sheets in the radial direction, and the tooth portion extends in the axial direction, that is, in the direction in which the magnetic flux flows. Loss can be reduced.

  In order to use an axial gap type rotating electrical machine to which such a wound core is applied as an automobile device, a method for manufacturing the wound core becomes a problem. For example, a conventional motor manufacturing method has been proposed in which a punched portion is made common by collectively manufacturing a stator core and a rotor core to reduce production costs (see, for example, Patent Document 1). Further, a protrusion or a notch is formed on each of the belt-like body of the electromagnetic steel sheet and the disk member around which the belt-like body is wound, and the protrusion and the notch are fitted when the belt-like body is wound around the disk member. Has proposed a method of manufacturing a wound core that prevents unwinding and improves production efficiency (see, for example, Patent Document 2).

JP 2010-233324 A JP 2007-259557 A

  In the manufacturing methods of Patent Documents 1 and 2, since the slot opening is punched from the strip of the electromagnetic steel sheet, the ratio of the material portion of the punched portion to the material portion used as the back yoke portion and the tooth portion increases. . Therefore, there has been a problem that the utilization rate of the electromagnetic steel sheet is reduced, the production cost of the wound core is increased, and the price of the axial gap type rotating electrical machine is increased.

  Further, Patent Documents 1 and 2 do not mention the relationship between the tooth width and the slot width at the same diameter of the wound core, but in general, the wound core has a tooth width at the same diameter larger than the slot width. There is a tendency to be manufactured. And when using a wound core with a tooth width of the same diameter larger than the slot width, if one increases the magnet area in order to use the magnetomotive force of a magnet, one tooth faces both the N and S poles. There is a problem that the area to be processed increases and the loss increases.

The present invention has been made to solve the above-described problems. The ratio of the material portion of the punched portion to the material portion used as the back yoke portion and the tooth portion is reduced, and the utilization rate of the electromagnetic steel sheet is increased. An object of the present invention is to obtain a method of manufacturing a stator core for an axial gap type rotating electrical machine that can reduce production costs.
In addition, the present invention provides an axial gap type rotation in which the teeth width at the same diameter of the stator core is smaller than the slot width, and the area where one tooth faces both the N pole and the S pole is reduced, thereby reducing the loss. The purpose is to obtain an electric machine.

  According to the method of manufacturing a stator core for an axial gap type rotating electrical machine according to the present invention, the first core piece and the second core piece in the form of strips arranged in a line in the length direction of the core back part with the teeth parts parallel to each other, respectively. A belt-like body made of a magnetic material extending in the longitudinal direction with a certain width in a state where the teeth portion of the first core piece is placed in the opposite direction so as to be inserted between the teeth portions of the second core piece. A core piece punching step of punching from the core, and winding each of the first core piece and the second core piece punched from the belt-like body around the axis with the plate thickness direction as the radial direction, and the core back portion is in the radial direction And a step of producing a wound iron core in which the teeth portions are laminated in a radial direction. In the core piece punching step, the core back portion of the first core piece and the second core piece Above tee Between the teeth portion, between the core back portion of the second core piece and the teeth portion of the first core piece, and between the teeth portion of the first core piece and the teeth portion of the second core piece. Between the first punched portion having an inverted S shape between the first core piece, the core back portion of the first core piece and the teeth portion of the second core piece, and the core back portion of the second core piece An S-shaped second punched portion between the teeth portion of the first core piece and between the teeth portion of the first core piece and the teeth portion of the second core piece is the belt-like shape. It is punched alternately while feeding the body in the transport direction.

  According to the present invention, the belt-shaped first core piece and the second core piece arranged in a row in the length direction of the core back portion with the teeth portions parallel to each other, and the tooth portion of the first core piece as the second core piece. The material used for the core back part and the teeth part is punched out from a band-shaped body made of a magnetic material having a constant width and extending in the length direction in a state of being arranged in the opposite direction so as to be inserted between the teeth parts of The ratio of the material part of the part to be punched with respect to the part is reduced, the utilization rate of the electromagnetic steel sheet is increased, and the production cost can be reduced.

It is a principal part perspective view explaining the structure of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the stator of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part perspective view which shows the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part perspective view which shows the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part perspective view which shows the stator core of the axial gap type rotary electric machine of a comparative example. It is a figure explaining the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view which shows the die used for the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view explaining the punching state by the punching die in the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the winding state of the core piece in the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part perspective view which shows the stator core produced by La> Lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 12 is a front view illustrating a punched state by a punching die in the method for manufacturing the stator core illustrated in FIG. 11. It is a principal part perspective view which shows the stator core produced by La = Lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 14 is a front view illustrating a punched state by a punching die in the method for manufacturing the stator core illustrated in FIG. 13. It is a principal part perspective view which shows the stator core produced by La <Lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 16 is a front view illustrating a punched state by a punching die in the method for manufacturing the stator core shown in FIG. 15. It is a principal part enlarged view of the stator core shown by FIG. It is a principal part perspective view which shows the stator core produced by la> lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 19 is a front view illustrating a punched state by a punching die in the method for manufacturing the stator core shown in FIG. 18. It is a principal part perspective view which shows the stator core produced by la = lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 21 is a front view illustrating a punching state by a punching die in the method for manufacturing the stator core shown in FIG. 20. It is a principal part perspective view which shows the stator core produced by la <lb in the axial gap type rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 23 is a front view illustrating a punched state by a punching die in the method for manufacturing the stator core illustrated in FIG. 22. It is a figure explaining the punching method of the stator core of the conventional axial gap type rotary electric machine. It is a figure explaining the manufacturing method of the stator core of the axial gap type rotary electric machine which concerns on Embodiment 2 of this invention. It is a perspective view which shows the stator core of the axial gap type rotary electric machine which concerns on Embodiment 3 of this invention. It is a perspective view which shows the stator core of the axial gap type rotary electric machine which concerns on Embodiment 4 of this invention.

Embodiment 1 FIG.
FIG. 1 is a perspective view of a main part for explaining the configuration of an axial gap type rotating electric machine according to Embodiment 1 of the present invention, and FIG. 2 is a perspective view showing a stator of the axial gap type rotating electric machine according to Embodiment 1 of the present invention. FIGS. 3 and 3 are perspective views showing the main part of the stator core of the axial gap type rotating electric machine according to Embodiment 1 of the present invention. In FIG. 2, only one concentrated winding coil is shown for convenience.

  1 to 3, an axial gap type rotating electrical machine 100 is made of an agglomerated nonmagnetic material such as stainless steel, and is attached to a rotating shaft (not shown) coaxially, and an annular rotor support member 2, and A rotor 1 having permanent magnets 3 constituting magnetic poles, which are arranged so as to penetrate the outer peripheral side of the rotor support member 2 and arranged at equal intervals in the circumferential direction, and teeth 6b are each an annular flat plate The stator core 6 is vertically projected from one surface of the core back 6a and extends in the radial direction, and is wound around the stator core 6 and arranged in a circumferential direction at an equiangular pitch. And a stator 5 having a stator winding 7.

  The permanent magnet 3 is magnetized in the axial direction of the rotating shaft so that both surfaces thereof become N pole and S pole, respectively, and the polarity of the surface on one side in the axial direction of the rotating shaft is alternately N pole and S pole in the circumferential direction. It is arranged to be. The rotor 1 is disposed in a housing (not shown) made of a nonmagnetic material, with the rotating shaft rotatably supported.

  As will be described later, the stator core 6 is a wound core produced by winding a belt-like body of an electromagnetic steel sheet around the axis with the plate thickness direction as a radial direction and winding it in a so-called plane winding. Each of the stator windings 7 is composed of a plurality of concentrated winding coils manufactured by intensively winding a conductor wire around one tooth 6b. The stator 5 is arranged coaxially so that the teeth 6b face the rotor 1 and face the rotor 1, and the other surface of the core back 6a is fixed to the housing and held by the housing.

  In this axial gap type rotating electrical machine 100, the stator 5 is disposed coaxially with the teeth 6b facing the rotor 1 and facing the rotor 1 with a certain gap therebetween, and is orthogonal to the axial direction. The surface becomes the torque transmission surface. Here, since the permanent magnets 3 are arranged on the concentric circles at an equiangular pitch, the permanent magnets 3 are formed in a substantially sector shape in which the circumferential dimension is wider toward the outer side in the radial direction, and the generated magnetic flux is larger toward the outer side in the radial direction. Become. Therefore, in order to effectively use the magnetomotive force of the permanent magnet 3, the cross-sectional shape orthogonal to the rotation axis of the tooth 6b is a tapered shape in which the circumferential width becomes wider toward the radially outer side. In the stator core 6, the circumferential width Wt of the tooth 6b is narrower than the circumferential width Ws of the slot 6c having the same diameter.

The axial gap type rotating electrical machine 100 configured as described above can achieve a high torque density, can have a flat structure, is disposed between the engine and the transmission, and is connected to the output shaft. Then, the DC power of the on-vehicle battery is converted into AC power and supplied to the stator winding 7. Thereby, a rotating magnetic field is given to the permanent magnet 3 of the rotor 1, the rotor 1 is driven, and the axial gap type rotary electric machine 100 is operated as a motor. The rotational torque of the rotor 1 is transmitted to the wheels and becomes the driving force of the vehicle.
Moreover, since the axis | shaft of the rotor 1 is connected with the driving wheel at the time of deceleration of a vehicle, the rotor 1 is rotated from the wheel side. As a result, a three-phase AC voltage is induced in the stator winding 7, and the axial gap type rotating electrical machine 100 operates as a generator. The alternating current power induced in the stator winding 7 is converted into direct current power and supplied to a vehicle battery or an electric load.

  The axial gap type rotating electrical machine 100 can be reduced in size by being applied to other uses such as an elevator hoisting machine characterized by a flat structure.

  Here, the magnetic flux A emitted from the N pole of the permanent magnet 3 enters the tooth 6b as shown by an arrow in FIG. 1, flows in the tooth 6b in the axial direction of the rotating shaft, and reaches the core back 6a. Next, the magnetic flux A flows in the core back 6a in the circumferential direction, enters the adjacent tooth 6b, flows in the tooth 6b in the axial direction of the rotating shaft, and returns to the S pole of the permanent magnet 3 from the tip of the tooth 6b. Thus, the magnetic flux A generated by the permanent magnet 3 flows three-dimensionally in the stator core 6. On the other hand, in the radial gap type rotating electrical machine, the magnetic flux generated by the permanent magnet flows two-dimensionally in the same plane of the stator core in the radial direction and the circumferential direction. As described above, the axial gap type rotating electrical machine 100 and the radial gap type rotating electrical machine have different magnetic flux flows, but the motor torque generation principle is the same.

  Next, the effect of using the stator core 6 in the axial gap type rotating electrical machine 100 will be described with reference to FIGS. 4 and 5. 4 is a perspective view showing a main part of a stator core of an axial gap type rotating electric machine according to Embodiment 1 of the present invention, and FIG. 5 is a perspective view showing a main part of a stator core of an axial gap type rotating electric machine according to a comparative example. is there. The stator core 8 of the comparative example shown in FIG. 5 is manufactured by laminating thin electromagnetic steel plates in the axial direction of the rotating shaft. 4 and 5, arrow A indicates the flow of magnetic flux, and arrow B indicates eddy current.

First, as shown in FIG. 5, in the stator core 8 of the comparative example, the thin electromagnetic steel plates are laminated in the axial direction of the rotation axis with the plate thickness direction as the axial direction. The rolling direction is orthogonal, eddy current B is generated, and loss due to eddy current increases.
On the other hand, in the stator core 6, since the thin electromagnetic steel plates are laminated in the radial direction with the plate thickness direction as the radial direction, the magnetic flux A and the rolling direction of the electromagnetic steel plates are parallel, and the magnetic flux A is in the teeth 6b. Flows in the axial direction of the rotating shaft. Therefore, generation of eddy current B is suppressed, and loss due to eddy current is reduced.

  In the stator core 6 according to the first embodiment, the circumferential width Wt of the tooth 6b is narrower than the circumferential width Ws of the slot 6c having the same diameter. If the area of the permanent magnet 3 is the same, the area of the portion where one tooth 6b is opposed to both the north and south poles when Wt <Ws is one tooth 6b when Wt> Ws. It is smaller than the area of the portion facing both the N and S poles. Therefore, in order to effectively use the magnetomotive force of the permanent magnet 3, even if the area of the permanent magnet 3 is increased, one tooth 6b is opposed to both the north and south poles by setting Wt <Ws. The area of the portion is reduced, and the magnetomotive force of the permanent magnet 3 can be used effectively.

Further, by setting Wt and Ws of the same diameter to be Wt <Ws, as will be described later, the first and second belt-shaped first and second belts in which the teeth portions 11b are arranged in parallel and arranged in a line in the length direction of the core back portion 11a. The core pieces 11A and 11B are arranged in reverse so as to put the teeth portion 11b of the first core piece 11A between the teeth portions 11b of the first core piece 11B, so-called staggered linear two-row arrangement, It can be punched from the strip 10 of the electromagnetic steel sheet.
Here, the length direction of the core back portion 11a coincides with the circumferential direction in FIG.

  Next, a method for manufacturing the stator core 6 will be described with reference to FIGS. 6 and 7 are diagrams for explaining a method of manufacturing a stator core of an axial gap type rotating electric machine according to Embodiment 1 of the present invention. FIG. 8 is a front view showing a cutting die used in the method for manufacturing a stator core of an axial gap type rotating electric machine according to Embodiment 1 of the present invention. FIG. 8 (a) shows the first cutting die, FIG. 8B shows a second punching die. FIG. 9 is a front view for explaining a punching state by a punching die in the method for manufacturing the stator core of the axial gap rotating electrical machine according to the first embodiment of the present invention. FIG. 10 is a view for explaining a winding state of the core piece in the method for manufacturing the stator core of the axial gap type rotating electric machine according to the first embodiment of the present invention. FIG. 10 (a) is a front view thereof, FIG. 10 (b) is a sectional view thereof.

  As shown in FIG. 7, the production line for the stator core 6 includes a pilot pin part punching area 25, a tooth part punching area 26, and a pilot pin part cutting area 27 in this order in the transport direction of the belt-like body 10. Has been placed.

In the pilot pin portion punching area 25, pilot pin portion punching die (not shown) for punching the pilot pin portion 12 is installed at each of both ends in the width direction of the belt-like body 10.
As shown in FIGS. 8A and 8B, the first and second punching dies 13 and 14 are arranged between the core back portion 11a and the teeth portion 11b of the first and second core pieces 11A and 11B. And it is formed in the substantially S shape or reverse S shape which can punch out between the teeth parts 11b. In the tooth part punching area 26, the first and second punching dies 13 and 14 are installed by separating the second punching die 14 in the transport direction of the first punching die 13.
The pilot pin portion cutting area 27 is provided with a punching die (not shown) for punching out both end portions in the width direction of the strip 10 together with the pilot pin portion 12.

  First, a drum (not shown) in which a strip 10 made of a thin electromagnetic steel plate extending in the length direction with a certain width is wound around a winding drum in a roll shape is installed in a production line. Then, the belt-like body 10 fed out from the drum is conveyed to the production line.

  Then, the belt-like body 10 is conveyed to the pilot pin part punching area 20. In the pilot pin part punching area 25, the pilot pin part 12 is punched into each of both end portions in the width direction of the strip 10 at a constant interval in the transport direction. The belt-like body 10 is moved in the transport direction by using a pilot pin portion 12 by a servo motor (not shown).

  Next, the belt-like body 10 from which the pilot pin portion 12 is punched is conveyed to the tooth portion punching area 26. In the tooth part punching area 26, first, by the first punching die 13, between the core back part 11a of the first core piece 11A and the tooth part 11b of the second core piece 11B, the core back part 11a of the second core piece 11B, A substantially inverted S-shaped first punching portion 15a is punched between the tooth portion 11b of the first core piece 11A and between the tooth portions 11b of the first and second core pieces 11A and 11B. Next, the belt-like body 10 is conveyed forward in the conveying direction, and the second punching die 14 is used to place the second core piece 11B between the core back portion 11a of the first core piece 11A and the tooth portion 11b of the second core piece 11B. A substantially S-shaped second punching portion 15b is punched between the core back portion 11a and the tooth portion 11b of the first core piece 11A and between the tooth portions 11b of the first and second core pieces 11A and 11B. At this time, the first and second punched portions 15a and 15b are punched by overlapping with the overlap portion 16, as shown in FIG.

  As shown in FIG. 6, the band-like body 10 is first punched by the first punching die 13 and the second punching die 14 and conveyed to the pilot pin cutting area 27. Is done. In the pilot pin portion cutting area 27, as shown in FIG. 7, both end portions in the width direction of the belt-like body 10 are cut together with the pilot pin portion 12, and the teeth portions 11b protrude from the core back portion 11a in the width direction, respectively. The first and second core pieces 11A and 11B arranged in the length direction of the portion 11a are manufactured.

  Next, the first and second core pieces 11A and 11B are separated and wound around the disk member 17 in a plane winding. The disk member 17 includes a shaft portion 17a around which the first core piece 11A or the second core piece 11B is wound, a holding portion 17b that holds the first core piece 11A or the second core piece 11B wound around the shaft portion 17a, Is provided. 11 A of 1st core pieces apply the end surface on the opposite side to the teeth part 11b of the core back part 11a to the holding | maintenance part 17b, the one surface is followed to the outer peripheral surface of the axial part 17a, and an edge part is fixed to the axial part 17a. The Then, as shown in FIG. 10, while applying tension to the first core piece 11A, the disk member 17 is rotated around the axis of the shaft portion 17a to wind the first core piece 11A around the shaft portion 17a. Next, the first core piece 11A is cut, the first core piece 11A wound around the shaft portion 17a is temporarily fixed by welding or the like, and the wound first core piece 11A is removed from the shaft portion 17a. Then, the removed first core piece 11A that has been removed is impregnated with resin, and the stator core 6 is manufactured. Similarly, the second core piece 11B is also manufactured as the stator core 6.

  Here, the teeth 6b have a tapered shape in which the circumferential width Wt becomes wider outward in the radial direction. Moreover, since the stator core 6 is a wound core produced by winding the first and second core pieces 11A, 11B into a planar winding, the pitch between the teeth 6b increases radially outward. Therefore, the plate thickness of the belt-like body 10 and the outer diameter of the shaft portion 17a are input to a control device (not shown), and the first punching die is removed for each of the punching steps by the first and second punching dies 13,14. The punching pitch τ1 between the first punching die 13 and the punching pitch τ2 between the first punching die 13 and the second punching die 14 is calculated, and the drive of the servo motor is controlled based on the calculated value. As a result, the belt-like body 10 is transported to the teeth part punching area 21 with the feed pitch adjusted for each of the punching steps by the first and second punching dies 13 and 14.

  Thereby, as FIG. 6 shows, the overlap part 16 of the 1st and 2nd punching parts 15a and 15b becomes small gradually toward the back of a conveyance direction. Further, in each of the first and second core pieces 11A and 11B, the width of the teeth portion 11b is gradually increased toward the rear in the transport direction, and the pitch between the teeth portions 11b is gradually increased toward the rear in the transport direction. It has become. Therefore, the first and second core pieces 11A and 11B are wound around the shaft portion 17a with the teeth portion 11b overlapped on the tooth portion 11b on which the tooth portion 11b has been wound in advance, with the width center being coincident. And the width | variety of the teeth part 11b piled up in radial direction becomes a taper shape which becomes wide gradually toward radial direction outward. The core back portion 11a is overlapped in the radial direction to become the core back 6a, and the tooth portion 11b is overlapped in the radial direction to become the tooth 6b.

  Below, the shape of the front-end | tip part of the teeth 6b facing the rotor 1 is demonstrated. FIG. 11 is a perspective view of a main part showing a stator core manufactured with La> Lb in the axial gap type rotating electric machine according to Embodiment 1 of the present invention, and FIG. 12 is in the method for manufacturing the stator core shown in FIG. FIG. 13 is a front view showing a punched state by a punching die, FIG. 13 is a perspective view of a main part showing a stator core manufactured at La = Lb in the axial gap type rotating electric machine according to Embodiment 1 of the present invention, and FIG. FIG. 15 is a front view illustrating a punching state by a punching die in the method for manufacturing the stator core shown in FIG. 13, and FIG. 15 is a diagram illustrating a fixing manufactured with La <Lb in the axial gap type rotating electric machine according to the first embodiment of the present invention. FIG. 16 is a front view showing a punching state by a punching die in the method for manufacturing the stator core shown in FIG. 15, and FIG. Punching method of a stator core of a conventional axial gap type rotating electric machine is a diagram illustrating a.

  In the conventional method for manufacturing a stator core of an axial gap type rotating electrical machine, as shown in FIG. 24, pilot pin portions 31 are punched at both ends in the width direction of the strip-shaped body 30, and then the strip-shaped body 30 is pilot-pinned. The punching pitch is adjusted using the portion 31 and conveyed, and the slot punching portion 32 is punched into the strip 30 at the adjusted pitch. Next, both end portions in the width direction of the belt-like body 30 are cut together with the pilot pin portion 31, and the core piece 34 including the core back portion 34a and the tooth portion 34b is manufactured. And the core piece 34 is wound up by the axial part 17a (not shown), and a stator core is produced.

  At this time, since the slot part punching part 32 enters the cutting part 33 cut together with the pilot pin part 31, the punching surface of the slot part punching part 32 and the punching surface of the cutting part 33 by the punching die Appear at both corners 35 in the width direction at the tip of the tooth portion 34b. Therefore, the shape of the width direction corner portion 35 at the tip end portion of the tooth portion 34b is an edge shape where the punching surface of the slot punching portion 32 and the punching surface of the cutting portion 33 intersect.

  In the present invention, as described above, the core back portion 11a and the second core of the first core piece 11A of the strip 10 are formed using the inverted S-shaped first punch 13 and the S-shaped second punch 14. Between the tooth part 11b of the piece 11B, between the core back part 11a of the second core piece 11B and the tooth part 11b of the first core piece 11A, and the tooth part 11b of the first core piece 11A and the second core piece 11B. Punching through. Therefore, the width La of the portion of the first punching die 13 and the width Lb of the portion of the second punching die 14 that punch out between the core back portion 11a of the first core piece 11A and the teeth portion 11b of the second core piece 11B. Due to the size relationship, an edge portion is formed on the tip surface of the tooth portion 11b of the second core piece 11B.

  When La> Lb, as shown in FIG. 12, in the overlap portion 16, the end of the second punched portion 15b is included in the first punched portion 15a. Therefore, one intersection 17a between the first punched portion 15a and the second punched portion 15b appears near the center in the width direction of the tip portion of the tooth portion 11b. The distance Lc 'between the one end of the tooth portion 11b punched out by the first punching die 13 and the intersecting portion 17a is constant, and the shape thereof is an edge shape. As a result, as shown in FIG. 11, the surface of the teeth 6b of the stator core 6 that faces the rotor 1 is formed at the center in the circumferential direction with the edge shape formed by the intersecting portions 17a continuing in the axial direction. And a shearing surface boundary 18a.

  In the case of La = Lb, as shown in FIG. 14, the intersecting portions 17a and 17b of the first punched portion 15a and the second punched portion 15b are the center in the width direction of the tip portion of the tooth portion 11b of the second core piece 11B. In the vicinity, two places appear on both sides of the overlap portion 16. The distance Lc ′ between one end of the tooth portion 11b punched by the first punching die 13 and the intersecting portion 17a is constant, and the distance between the other end of the tooth portion 11b punched by the second punching die 14 and the intersecting portion 17b is constant. The distance Lc between them is constant, and their shape is an edge shape. As a result, as shown in FIG. 13, the surfaces of the teeth 6b of the stator core 6 facing the rotor 1 have edge shapes formed by the intersecting portions 17a and 17b at two locations in the center in the circumferential direction. Shear surface boundaries 18a and 18b are formed continuously in the axial direction.

  In the case of La <Lb, as shown in FIG. 16, in the overlap portion 16, the end portion of the first punched portion 15a is included in the second punched portion 15b. Therefore, one intersection 17b between the first punched portion 15a and the second punched portion 15b appears near the center in the width direction of the tip portion of the tooth portion 11b of the second core piece 11B. The distance Lc between the other end of the tooth portion 11b punched out by the second punching die 14 and the intersecting portion 17b is constant, and the shape thereof is an edge shape. As a result, as shown in FIG. 15, the surface of the teeth 6b of the stator core 6 facing the rotor 1 is formed at the center in the circumferential direction with the edge shape formed by the intersecting portions 17b continuing in the axial direction. And a shearing surface boundary 18b.

  In FIG. 11, the boundary 18a of the shear plane is shown by a curve in which the edge shape by the intersecting portion 17a is continuous in the axial direction, but actually, it is adjacent in the axial direction as shown in FIG. The edge shape of the teeth portion 11b is a discontinuous shape shifted in the circumferential direction. That is, when the stator iron core 6 is manufactured, the punching pitch of the teeth portion 11b is adjusted in consideration of the thickness of the electromagnetic steel sheet, and ideally, the first and first windings wound around the shaft portion 17a. Although the edge shapes of the tooth portions 11b adjacent in the axial direction of the two-core pieces 11A and 11B coincide with each other, the edge shapes of the tooth portions 11b adjacent in the axial direction are actually shifted in the circumferential direction. Further, in FIGS. 13 and 15, the boundary 18a, 18b of the shear plane is shown by a curved line in which the edge shape by the intersecting portions 17a, 17b is continuous in the axial direction. The edge shape of 11b becomes a discontinuous shape shifted in the circumferential direction. In addition, since both end corners in the circumferential direction of the tooth portion 11b are formed by punching at the L-shaped portions of the first punching die 13 and the second punching die 14, the shape thereof becomes an R shape.

  Next, the shape of the bottom surface of the slot 6c facing the rotor 1 will be described. 18 is a perspective view of a main part showing a stator core manufactured by la> lb in the axial gap type rotating electric machine according to the first embodiment of the present invention, and FIG. 19 is a diagram of the method for manufacturing the stator core shown in FIG. FIG. 20 is a front view illustrating a punched state by a punching die, FIG. 20 is a perspective view of a main part illustrating a stator core manufactured by la = lb in the axial gap type rotating electric machine according to Embodiment 1 of the present invention, and FIG. FIG. 22 is a front view for explaining a punching state by a punching die in the method for manufacturing the stator core shown in FIG. 20, and FIG. 22 is a fixing manufactured at la <lb in the axial gap type rotating electric machine according to the first embodiment of the present invention. FIG. 23 is a front view illustrating a punching state by a punching die in the method for manufacturing the stator core shown in FIG. 22.

  In the case of la> lb, as shown in FIG. 19, in the overlap portion 16, the end of the second punched portion 15b is included in the first punched portion 15a. Therefore, one intersection 19a between the first punched portion 15a and the second punched portion 15b appears near the center in the width direction of the bottom of the slot portion. The distance lc 'between one end of the bottom portion of the slot portion punched out by the first punching die 13 and the intersecting portion 19a is constant, and the shape thereof is an edge shape. Thus, as shown in FIG. 18, the bottom surface of the slot 6c of the stator core 6 facing the rotor 1 is formed at the center in the circumferential direction with the edge shape formed by the intersecting portions 19a being continuous in the axial direction. And a shearing surface boundary 20a.

  In the case of la = lb, as shown in FIG. 21, the intersecting portions 19a and 19b of the first punched portion 15a and the second punched portion 15b are located near the center in the width direction of the bottom portion of the slot portion. Appears in two places on both sides. The distance lc 'between one end of the bottom of the slot portion punched by the first punching die 13 and the intersection 19a is constant, and the other end of the bottom of the slot punched by the second punching die 14 and the intersection 19b. The distance lc between the two is constant, and their shape is an edge shape. Accordingly, as shown in FIG. 20, the bottom surfaces of the slots 6c of the stator core 6 that face the rotor 1 have edge shapes formed by the intersecting portions 19a and 19b at two locations in the circumferential central portion, respectively. Shear surface boundaries 20a and 20b are formed continuously in the axial direction.

  In the case of la <lb, as shown in FIG. 23, in the overlap portion 16, the end of the first punched portion 15a is included in the second punched portion 15b. Therefore, one intersection 19b between the first punched portion 15a and the second punched portion 15b appears near the center in the width direction of the bottom of the slot portion. The distance lc between the other end of the bottom of the slot portion punched out by the second punching die 14 and the intersecting portion 19b is constant, and the shape thereof is an edge shape. Accordingly, as shown in FIG. 22, the bottom surface of the slot 6c of the stator core 6 facing the rotor 1 is formed at the center in the circumferential direction with the edge shape formed by the intersecting portions 19b being continuous in the axial direction. And a shearing surface boundary 20b.

  In FIG. 19, FIG. 21, and FIG. 23, the boundary 20a, 20b of the shear plane is shown by a curve in which the edge shape by the intersecting portions 19a, 19b is continuous in the axial direction. Similarly to the boundary 18a, 18b of the shear plane shown in FIGS. 13 and 15, the edge shape of the teeth portion 11b adjacent in the axial direction is a discontinuous shape shifted in the circumferential direction. In addition, since both end corners in the circumferential direction of the bottom portion of the slot portion are formed by punching at the L-shaped portions of the first punching die 13 and the second punching die 14, respectively, the shape thereof becomes an R shape.

  Here, the description has been given of the case where the boundary 18a, 18b, 20a, 20b of the shear plane is formed at the tip of the tooth 6b of the second core piece 11B or the bottom of the slot 6c. It goes without saying that the two-core piece 11B may be formed at both the tip of the tooth 6b and the bottom of the slot 6c.

  Moreover, although the case where the boundary 18a, 18b, 20a, 20b of the shear plane is formed at the tip of the tooth 6b of the second core piece 11B and the bottom of the slot 6c has been described, the second core piece 11B from the strip 10 is explained. At the same time, the front end surface of the slot portion of the first core piece 11A and the center portion in the circumferential direction of the bottom portion of the slot portion also have a shear surface due to the size relationship between La and Lb and the size relationship between la and lb. One or two boundaries are formed. As described above, the boundary of the shearing surface is provided at the center in the circumferential direction of at least one of the tip of the tooth 6b and the bottom of the slot 6c facing the rotor 1.

  As described above, according to the first embodiment, the first and second core pieces 11A and 11B in the form of strips arranged in a line in the length direction of the core back portion 11a with the teeth portions 11b parallel to each other are A so-called zigzag straight two-row arrangement arranged in the opposite direction so that the teeth 11b of the core piece 11A are placed between the teeth 11b of the second core piece 11B is punched out from the strip 10 of the electromagnetic steel sheet. Since it is sewn, the ratio of the material part of the part punched with respect to the material part used for the core back part 11a and the teeth part 11b decreases, the utilization factor of an electromagnetic steel plate can be raised, and production cost can be reduced.

  Further, since the first and second punching dies 13 and 14 are made to have an overlap portion 16 between the first and second punching portions 15a and 15b, the first core piece 11A and the second core piece There is no need to prepare a dedicated die for separating 11B, the pressing process can be simplified, and the manufacturing cost of the stator core 6 can be reduced.

  If there is an edge portion in the magnetic body placed in the magnetic field, the magnetic flux concentrates on the edge portion, and the magnetic flux density near the edge portion increases. Moreover, in a rotary electric machine, the magnetic flux density of the both ends of the teeth in the circumferential direction among the gaps between the teeth of the stator core and the rotor increases. Therefore, when both ends in the circumferential direction of the teeth have an edge shape like a stator core produced by a conventional manufacturing method, both ends in the circumferential direction of the teeth are magnetically saturated, and the torque characteristics of the rotating electrical machine are reduced. To do. In the stator core 6 produced by the manufacturing method according to the first embodiment, the edge shape is in the circumferential central portion where the magnetic flux density is smaller than both circumferential ends of the teeth 6b, and both circumferential ends of the teeth 6b are Since it has an R shape, magnetic saturation can be suppressed and a decrease in torque characteristics can be prevented.

  In the first embodiment, the first and second core pieces 11A and 11B are wound in a plane winding so that the tooth portion 11b constituting each tooth 6b overlaps in the radial direction with the center of the width thereof aligned with the radial direction. The first and second core pieces 11A, 11a, 11b, and 11c are arranged so that the tooth portions 11b constituting the teeth 6b overlap in the radial direction so that the width centers thereof coincide with the direction inclined at a certain angle with respect to the radial direction. 11B may be wound into a plane winding.

Embodiment 2. FIG.
FIG. 25 is a diagram for explaining a method for manufacturing a stator core of an axial gap type rotating electric machine according to Embodiment 2 of the present invention.

  First, as shown in (a) of FIG. 25, the first punching die 13 substantially reduces the space between the core back portion 11a and the tooth portion 11b and between the tooth portions 11b of the first and second core pieces 11A and 11B. Punched into a reverse S shape. As a result, the first first punched portion 15 a 1 is punched from the belt-like body 10. Next, as shown in FIG. 25 (b), the belt-like body 10 is conveyed by δ1 forward in the conveying direction, and punching by the first punching die 13 is performed. As a result, the second first punching portion 15a2 that extends the first first punching portion 15a1 by δ1 rearward in the transport direction is punched from the belt-like body 10. Next, as shown in FIG. 25C, the belt-like body 10 is conveyed by δ2 forward in the conveying direction, and punching by the first punching die 13 is performed. As a result, the third first punching portion 15a3 that extends the first and second first punching portions 15a1 and 15a2 by δ2 rearward in the transport direction is punched from the belt-like body 10 to become the set first punching portion 15a.

  Next, as shown in FIG. 25 (d), the second punching die 14 allows the first and second core pieces 11A and 11B to be substantially spaced between the core back portion 11a and the tooth portion 11b and between the tooth portions 11b. Punched into an S shape. As a result, the first second punched portion 15b1 is punched from the belt-like body 10. Next, as shown in FIG. 25 (e), the belt-like body 10 is transported by δ3 forward in the transport direction, and punching by the second punching die 14 is performed. As a result, the second second punching portion 15b2 that extends the first second punching portion 15b1 rearward in the transport direction by δ3 is punched from the belt-like body 10. Next, as shown in FIG. 25 (f), the belt-like body 10 is transported by δ 4 forward in the transport direction, and punching by the second punching die 14 is performed. As a result, the third second punching portion 15b3 that extends the first and second second punching portions 15b1 and 15b2 by δ4 rearward in the transport direction is punched from the belt-like body 10 to become the set second punching portion 15b.

  In the first embodiment, since the punching portions 15a and 15b are punched by one shot of the first and second punching dies 13 and 14, the punching pitch τ1 between the first punching dies 13 and the first punching dies 13 are cut. Although the punching pitch τ2 between the second punching die 14 and the second punching die 14 can be adjusted, the spacing between the tooth portions 11b of the first and second core pieces 11A, 11B is constant. In the second embodiment, the punched portions 15a and 15b are punched by continuously performing the punched portion punching process of feeding the strip 10 and one shot of the first and second punch dies 13 and 14 three times. Therefore, not only the punching pitch τ1 between the first punching die 13 and the punching pitch τ2 between the first punching die 13 and the second punching die 14, but also the teeth portions of the first and second core pieces 11A and 11B. The interval between 11b can be adjusted. Therefore, it is possible to improve the dimensional accuracy of the circumferential width and arrangement pitch of the teeth 11b of the first and second core pieces 11A and 11B, and the stator core 6 can be optimally designed.

In the second embodiment, the punched portion 15a, 15b is punched by continuously performing the punched portion punching process of feeding the strip 10 and one shot of the first and second punch dies 13, 14 three times. However, the continuous number of times of the punched portion punching process of feeding the belt-like body 10 and one shot of the first and second punching dies 13 and 14 is not limited to three, and may be two or more.
Moreover, in the said Embodiment 2, although the same punching die is used at each punching part punching process, you may use a different punching die for every punching part punching process.

  By applying the two stator cores according to the second embodiment to the double stator type axial gap type rotating electrical machine, the same part of the electromagnetic steel sheet can be used for the two stator cores, and the rolling direction of the electromagnetic steel sheet Quality variation due to position can be eliminated, and the performance of the rotating electrical machine can be improved.

Embodiment 3 FIG.
FIG. 26 is a perspective view showing a stator core of an axial gap type rotating electric machine according to Embodiment 3 of the present invention.

In FIG. 26, the stator core 6A has flanges 6d that protrude from the tip of the tooth 6b to both sides in the circumferential direction.
Other configurations are the same as those in the first embodiment.

  According to the third embodiment, since the flange portion 6d protrudes from the tip end portion of the tooth 6b to both sides in the circumferential direction, a sudden change of the magnetic flux from the permanent magnet 3 between the teeth 6b is alleviated, and the rotor Torque pulsation when 1 rotates can be suppressed, and vibration can be reduced.

Embodiment 4 FIG.
FIG. 27 is a perspective view showing a stator core of an axial gap type rotating electric machine according to Embodiment 4 of the present invention.

In FIG. 27, the stator core 6B has teeth 6b protruding vertically from both surfaces of a core back 6a each formed of an annular flat plate, extending in the radial direction, and arranged at an equiangular pitch in the circumferential direction. It is configured.
Other configurations are the same as those in the first embodiment.

  A stator core 6B according to the fourth embodiment is a stator core applied to a double rotor type axial gap type rotating electrical machine, and is coaxial between a pair of rotors arranged coaxially apart from each other in the axial direction. And through a certain gap.

  In order to manufacture the stator core 6B, first, the first and second core pieces in the form of strips in which the teeth portions protrude on both sides in the width direction of the core back portion and are arranged in the length direction of the core back portion, A so-called zigzag linear two-row arrangement is arranged in the opposite direction so that the teeth of the core pieces are placed between the teeth of the second core piece, and punched out from the belt-like body of the electromagnetic steel sheet. Next, the first core piece (second core piece) is wound around a plane winding to produce the stator core 6B. Therefore, also in the fourth embodiment, the ratio of the material portion of the punched portion to the material portion used for the core back portion and the tooth portion is reduced, the utilization rate of the electromagnetic steel sheet is increased, and the production cost is reduced. Can do.

In each of the above embodiments, a rotor support member made of a massive non-magnetic material is used, but a rotor support member made of a massive magnetic material such as iron or a thin electromagnetic steel plate is laminated. A rotor support member manufactured in this manner may be used.
In each of the above embodiments, the stator winding 7 is composed of a plurality of concentrated winding coils produced by intensively winding a conductor wire around one tooth 6b. Each of the plurality of distributed winding coils may be formed by winding a conductor wire around a pair of slots 6c located on both sides of a plurality of teeth 6b continuous in the circumferential direction.

  DESCRIPTION OF SYMBOLS 1 Rotor, 2 Rotor support member, 3 Permanent magnet (magnetic pole), 5 Stator, 6, 6A, 6B Stator iron core, 6a Core back, 6b Teeth, 6d collar part, 7 Stator winding, 10 Strip | belt body 11A 1st core piece, 11B 2nd core piece, 11a Core back part, 11b Teeth part, 13 1st punching die, 14 2nd punching die, 15a 1st punching part, 15b 2nd punching part, 16 Overlap part .

Claims (7)

Each of the teeth protrudes axially from one surface of the core back, extends in the radial direction, and is a method of manufacturing a stator core for an axial gap type rotating electrical machine disposed at an equiangular pitch in the circumferential direction,
Each of the first core piece and the second core piece in the form of a strip arranged in a line in the length direction of the core back part with the tooth parts parallel to each other, the tooth part of the first core piece is the same as the second core piece. A core piece punching process for punching from a belt-shaped body made of a magnetic material extending in the length direction with a certain width in a state of being arranged in the opposite direction so as to be inserted between the teeth parts,
Each of the first core piece and the second core piece punched from the belt-like body is wound around the axis with the plate thickness direction as the radial direction, the core back portion is laminated in the radial direction, and the teeth portion And a step of producing a wound core laminated in the radial direction,
In the core piece punching step, between the core back portion of the first core piece and the teeth portion of the second core piece, the core back portion of the second core piece and the teeth of the first core piece. And an inverted S-shaped first punched portion between the teeth portion of the first core piece and the teeth portion of the second core piece, and the core back portion of the first core piece. And the teeth portion of the second core piece, between the core back portion of the second core piece and the teeth portion of the first core piece, and the teeth portion of the first core piece and the above Manufacture of a stator core for an axial gap type rotating electrical machine in which an S-shaped second punched portion between the second core piece and the tooth portion is punched alternately while feeding the belt-like body in the conveying direction. Method.   The first punched portion and the second punched portion that are alternately punched are between the core back portion of the first core piece and the teeth portion of the second core piece, and the above of the second core piece. The manufacturing method of the stator core for axial gap type rotary electric machines of Claim 1 which has overlapped between the core back part and the said teeth part of the said 1st core piece.   The said 1st punching part and the said 2nd punching part are each punched by performing the punching part punching process of feeding of the said strip | belt-shaped body and one shot of a punching die | die continuously several times, respectively. A method for manufacturing a stator core for an axial gap type rotating electrical machine according to claim 2.   The method of manufacturing a stator core for an axial gap type rotating electrical machine according to claim 3, wherein the punching die is the same in the punching part punching step performed continuously.   The method of manufacturing a stator core for an axial gap type rotating electrical machine according to claim 3, wherein the punching die is different for each of the punching part punching steps that are continuously performed. A rotor in which magnetic poles are arranged at equal intervals in the circumferential direction on the rotor support member;
Each of the teeth protrudes in the axial direction from one surface of the core back and extends in the radial direction, and the stator core disposed at an equiangular pitch in the circumferential direction, and the stator winding wound around the stator core. Having the teeth facing the rotor, and a stator disposed coaxially relative to the rotor,
The stator core is manufactured by winding strip-shaped core pieces arranged in a line in the length direction of the core back portion with the teeth portions in parallel around the axis with the plate thickness direction as the radial direction. Are laminated in the radial direction to constitute the core back, and the tooth portion is laminated in the radial direction to constitute the teeth,
The circumferential width of the teeth is narrower than the circumferential width of the slots of the same diameter,
An axial gap type rotating electrical machine having a boundary of a shearing surface in at least one circumferential center of a bottom surface of a slot formed between the tip surface of the teeth and the adjacent teeth.   The axial gap type rotating electrical machine according to claim 6, wherein the stator iron core has flange portions that protrude from both ends of the teeth toward the circumferential direction.

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