JP2020092531A - Stator, rotating electric machine using stator, and method for manufacturing stator - Google Patents

Abstract

To provide a stator having improved output efficiency and output density and high productivity, a rotating electric machine using the stator, and a manufacturing method of the stator.SOLUTION: A rotating electric machine stator 12 includes a core 2 that is obtained by laminating a plurality of thin plate-shaped core sheets 3 including a plurality of annularly arranged yoke portions 7, which extend in the circumferential direction, tooth portions 8 which extend in the radial direction from the yoke portion 7, and shoe portions 9 which extend in an arc shape in the circumferential direction at the tips of the tooth portions 8, and has protrusions 10 on either or both end faces of the upper and lower end faces in the laminating direction, an insulator 4 installed on the end face and having a hole portion 11 fitted to the protrusion 10, a slot cell 5 that covers both side surfaces in the circumferential direction of the core 2 and contacts the insulator 4 on the end surface side, and a coil 6 wound around the insulator 4 and the slot cell 5.SELECTED DRAWING: Figure 4

Description

The present invention relates to a stator, a rotating electric machine using this stator, and a method for manufacturing the stator.

Generally, in order to improve the output density of a rotating electric machine (output density=output/volume of the rotating electric machine), a copper wire is wound around a core with a winding frame (hereinafter referred to as “insulator”) of an insulating member of a stator interposed. There is a method of increasing the number of turns to increase the magnetic force during energization. Generally, by winding the copper wires while aligning them, it is possible to efficiently wind in a limited winding area. However, the alignment of the windings often deteriorates due to variations in member size, member fixing position, and assembly work.
Here, there is a method of absorbing the variation in the stacking height by providing the stacking direction elastic convex portion and the core stacking punching portion on the core sheet of the stator to suppress the deterioration of the alignment of the windings (for example, See Patent Document 1).
Further, in order to improve the efficiency of the rotating electric machine (efficiency=output/(output+loss)), the iron material of the stator is made of a core in which a plurality of thin-plate core sheets are laminated to reduce iron loss due to eddy current. There is a way. Generally, since the core sheet is manufactured by punching without caulking, the productivity is good, but eddy current increases due to conduction in the laminating direction at the caulking portion. As a countermeasure against this, there is a method of obtaining a core by adhering the layers (for example, refer to Patent Document 2).

Japanese Patent Laid-Open No. 2009-225588 JP, 2009-284631, A

In the invention described in Patent Document 1, for example, as shown in FIG. 1 of Patent Document 1, each thin plate is provided with a core laminating embossed portion, and one laminating end is provided with an elastic convex portion in the laminating direction. There is. As a result, it is possible to suppress the disturbance due to the change in the trace of the copper wire at the time of winding due to the variation in the stacking height, so it is expected that the alignment of the windings will be improved, but the output due to the influence of the stacking embossed part on each thin plate Efficiency is reduced.
In the invention described in Patent Document 2, since adjacent core sheets are fixed to each other by adhesion and stacked and fixed by punching and caulking, eddy currents can be eliminated, but by securing the curing time of the adhesive, the production lead time is reduced. become longer.

The present invention has been made to solve the above problems, and provides a stator that can improve output efficiency and output density and has high productivity, a rotating electric machine that uses this stator, and a method for manufacturing the stator. The purpose is to do.

A plurality of stators of a rotating electric machine according to the present invention are arranged in an annular shape, and have a yoke portion extending in a circumferential direction, a tooth portion extending in a radial direction from the yoke portion, and a circular shape in a circumferential direction at tips of the tooth portions. A plurality of thin plate-shaped core sheets composed of shoe portions extending in an arc shape are laminated, and a core having a protrusion on one or both end faces of the upper and lower end faces in the laminating direction and a core installed on the end face are fitted to the protrusions. An insulator having a hole portion, a slot cell that covers both circumferential side surfaces of the core and abuts on the insulator on the end surface side, and an insulator and a coil wound around the slot cell are provided.
A method of manufacturing a stator of a rotating electric machine according to the present invention comprises a step of punching and forming core sheets of the number of laminated sheets from a magnetic material, and a step of press-forming a protrusion on one of the core sheets of the number of laminated sheets, The process of discharging the core sheet manufactured by repeating the punching process and the press-molding process from the press machine to the aligning and conveying unit, and inserting the cutout portion into the gap between the core sheets by the protrusions and A step of cutting out the core sheet bundle, a step of assembling the slot cells on both side surfaces of the core sheet bundle in the stacking direction, and a step of fitting the hole portion of the insulator to the end surface of the core sheet bundle in the stacking direction according to the protrusions. And a step of winding a coil around a core sheet bundle in which the slot cells and the insulators are assembled to form a magnetic pole, and a step of assembling a plurality of magnetic poles in an annular shape.

According to the stator and the rotating electric machine using the stator according to the present invention, the core sheets forming the core are not fixed by punching or welding, and the core sheets do not conduct with each other. Eddy current loss is suppressed, and a highly efficient rotating electrical machine can be obtained.
Further, slot cells can be aligned and mounted on the side surfaces of the stacked cores, and the insulators are fixed to the upper and lower end surfaces of the cores in the stacking direction with good positional accuracy. Can be wound. Furthermore, since it can be fixed without providing protrusions in the winding area of the core or the inner and outer circumferences, more copper wire can be wound without reducing the winding area, and the gap between the inner circumference of the stator and the outer circumference of the rotor due to the projections. Since there is no expansion of (hereinafter referred to as a gap) or expansion of the outer peripheral diameter of the stator, a rotating electric machine having a good output density can be obtained.
According to the stator manufacturing method of the present invention, a gap is formed by the protrusions for each predetermined number of laminated sheets in the bundle of core sheets discharged from the press, and the required number of core sheets can be easily cut out. Can be reduced. Further, since the stacking height of the cut core can be easily adjusted by adjusting the press molding timing of the core sheet having the protrusions on the press side, the setup work can be simplified and the productivity can be improved.

FIG. 3 is a diagram showing one magnetic pole in the stator according to the first embodiment. FIG. 4 is a diagram showing a core of one magnetic pole in the stator according to the first embodiment. FIG. 3 is a diagram showing an insulator of one magnetic pole in the stator according to the first embodiment. FIG. 4 is an exploded view of one magnetic pole (not including a coil) in the stator according to the first embodiment. It is a figure which shows the rotary electric machine which concerns on Embodiment 1. FIG. 6 is a diagram showing a method of manufacturing the stator according to the first embodiment. FIG. 5 is a diagram showing a method for manufacturing protrusions on the core sheet of the stator according to the first embodiment. FIG. 6 is a diagram showing an example of a transport rail of a core sheet aligning and transporting unit in the stator manufacturing method according to the first embodiment. FIG. 7 is a diagram showing magnetic poles in which three poles are connected in the stator according to the second embodiment. FIG. 7 is a diagram showing a core sheet in which three poles are connected in the stator according to the second embodiment. It is a figure which shows the stator which concerns on the modification of Embodiment 2. FIG. 11 is a diagram showing an example of a transport rail of a linked core sheet aligning and transporting unit in the stator manufacturing method according to the second embodiment.

Hereinafter, modes for carrying out the present invention will be described in detail with reference to the drawings.

Embodiment 1
Generally, a core for a stator of a rotary electric machine is divided into magnetic pole teeth units and a plurality of core sheets made of a magnetic material are laminated and fixed. FIG. 1 shows one magnetic pole 1 constituting a stator 12 (shown in FIG. 5 described later) according to the first embodiment. 1A is a perspective view of the magnetic pole 1, FIG. 1B is a top view of the magnetic pole 1, and FIG. 1C is a diagram showing a cross section (BB cross section) parallel to the stacking direction of the core 2. 1D is a side view of the magnetic pole 1, and FIG. 1E is a view showing a cross section (AA cross section) of the core 2 in the stacking direction.
As shown in FIG. 1A, the magnetic pole 1 includes a core 2, an insulator 4, a slot cell 5, and an insulating film, which are formed by laminating a plurality of core sheets 3 made of a magnetic material (for example, iron material) divided into magnetic pole teeth. The coil 6 is made of a copper wire (or an aluminum wire, etc.; hereinafter, only a copper wire will be described) formed with. The insulator 4 is made of an insulating resin (for example, PET resin (polyethylene terephthalate), nylon, etc.). The slot cell 5 is a film material made of a resin having an insulating property similar to the insulator 4.
As shown in the cross-sectional view taken along the line BB of FIG. 1(c), when the core 2 is arranged in an annular shape, the core sheet 3 is a yoke that extends in the circumferential direction so that the cores 2 adjacent in the circumferential direction are in contact with each other. The teeth portion 8 includes a portion 7, a tooth portion 8 extending from the yoke portion 7 in the direction of the center of the circle, and a shoe portion 9 extending in an arc shape in the circumferential direction at the tip of the tooth portion 8. Since the width of the teeth portion 8 in the circumferential direction is smaller than that of the yoke portion 7 and the shoe portion 9, a gap (hereinafter, referred to as a winding region 36) is formed between the adjacent teeth portions 8. The coil 6 is housed in the winding area 36 when viewed from the stacking direction of the core 2.

As shown in the AA cross-sectional view of FIG. 1(e), the core sheet 3a and the core sheet 3b on the upper and lower end surfaces of the core 2 are provided with protrusions 10 formed by press molding. The protrusion 10 projects in the thickness direction of the core sheet 3a or the core sheet 3b, and is formed by extruding a part of the core sheet 3a or the core sheet 3b.
FIG. 2 shows the core 2 used for the magnetic pole 1 in the stator 12 according to the first embodiment. 2A is a perspective view of the core 2, FIG. 2B is a side view of the core 2, FIG. 2C is a top view of the core 2, and FIG. 2D is a core in which the slot cell 5 is mounted. 2 shows the top view of FIG.
In FIG. 2B, the structure in which the projections 10 are provided on both the upper and lower end surfaces as shown in the sectional view taken along the line AA of FIG. 10 are provided. Here, for example, in the winding step at the time of manufacturing, the insulator near the winding start position of the coil is likely to be displaced, so that the protrusion 10 may be provided on the end surface on which the insulator is mounted.

In the first embodiment, as shown in FIG. 2, the protrusions 10 are provided at two locations that are symmetrical with respect to the circumferential centerline in the yoke portion 7 of the core sheet 3a and one location on the centerline of the teeth portion 8 for a total of three locations. It is formed and has a cylindrical shape with an outer diameter of 0.5 to 2 mm and a height of 0.2 to 1 mm.
The shape of the protrusion 10 may be a prismatic shape such as a triangular prism or a quadrangular prism other than the above-mentioned cylindrical shape, a pyramid shape such as a triangular pyramid or a quadrangular pyramid, a hemisphere or a semi-cylindrical shape, and press molding is possible The shape is not limited as long as the insulator 4 described later can be fixed by fitting with the protrusion 10. Further, the formation position and the number of the protrusions 10 are not limited as long as they can be press-molded and the insulator 4 described later can be fixed by the protrusions 10. For example, the yoke portion 7 and the tooth portion 8 may each have two locations on the center line, or a total of two locations on the center line in the radial direction of the core sheet 3 on the circumferential center line of the yoke portion 7. When the protrusion 10 has a round shape, it is desirable that a plurality of insulators 4 be provided so as not to rotate, but if the protrusion 10 has a rectangular shape, it is possible to fix even one.

In addition, in the stator according to the first embodiment, in order to suppress the coil winding disorder, one of the upper and lower end surfaces of the core 2 in the stacking direction or the core 4 can be attached to the end surface of the core 2 with high positional accuracy. Protrusions are provided on both end faces. As shown in FIG. 2, of the two end faces of the core 2 in the stacking direction, the protrusion 10 is provided on the end face of the core sheet 3a at the upper end, or as shown in FIG. May be. The shape, position, and quantity of the protrusions 10 are not limited as long as they can be press-molded and the insulator 4 can be fixed by fitting.

As shown in FIG. 1, the insulator 4 is installed so as to contact both end surfaces of the core 2 in the stacking direction. FIG. 3 is a perspective view of the pair of insulators 4 on both end surfaces of the core 2. When the insulator 4 contacts the upper and lower end surfaces of the core 2 in the stacking direction and is arranged in an annular shape together with the core 2, the first flange 4b extending in the circumferential direction on the outer peripheral side and the first flange 4b in the circular center direction. And a second flange 4c extending in a circular arc shape in the circumferential direction at the tip of the body portion 4a. The insulator 4 corresponds to both end surfaces of the core 2, the first flange 4b corresponds to the yoke portion 7 of the core 2, the body portion 4a corresponds to the tooth portion 8 of the core 2, and the second flange 4c corresponds to the shoe portion 9 of the core 2, respectively. Are arranged.
The insulator 4 has a function of electrically insulating between the core 2 and the coil 6, and holding the coil 6 at the winding position and the installation position of the slot cell 5.

As shown in FIG. 3, a hole 11 is provided in the contact surface 4d of the insulator 4 that contacts the core 2. The hole 11 has a circular shape into which the cylindrical protrusion 10 provided on the core sheet 3 can fit. Since the depth of the hole 11 is greater than or equal to the height of the protrusion 10, the end surface of the core 2 in the stacking direction and the contact surface 4d of the insulator 4 are installed without a gap.

In the stator of Embodiment 1, as shown in FIG. 3, three circular hole portions 11 are provided corresponding to the protrusions 10 shown in FIG. 2. For example, the insulator 4 is made of resin. This is not the case when the product can form the hole portion 11 that can be fitted to the protrusion 10 in the shape, position, and number described above.
Further, in the stator according to the first embodiment, the protrusion 10 is formed on only one end face of both end faces of the core 2 in the stacking direction, and therefore, for the insulator that abuts on the other end face without the protrusion 10, The hole 11 may not be formed.
In the stator according to the first embodiment, with respect to the fitting of the protrusion 10 and the hole 11, all the combinations of the three pairs of the protrusion and the hole are fitted so that the insulator 4 can be fixed. As long as it can be fixed, only two pairs or only one pair may be fitted. In addition, when the positions of the core 2 and the insulator 4 can be fixed via a jig, an allowable range may be provided for the fitting of the protrusion and the hole described above. It may be 0.1 mm larger than the outer diameter and may not be fitted precisely.

FIG. 4 shows an exploded view of the magnetic pole 1 (without the coil 6).
As shown in FIG. 4 (also shown in FIG. 1C and FIG. 2D), two slot cells 5 are provided per core so as to cover both side surface portions 2a of the core 2 in the circumferential direction. Will be placed. Specifically, the slot cell 5 is formed from the circumferential side surface 8 a of the tooth portion 8 of the core 2, the inner circumferential surface 7 a of the yoke portion 7 adjacent to the side surface 8 a on the circular center side, and the circular center of the shoe portion 9. It covers the outer peripheral surface 9a away from the outer peripheral surface 9a and abuts on the insulator 4 on the upper and lower end surface sides. That is, the slot cell 5 completely covers both side surface portions 2a of the core 2 in the winding region 36 when viewed from the cross section in the stacking direction of the core 2, and the stacked cores 2 are aligned, and the coil 6 and the core 2 to be described later are connected to each other. It has an insulation function to prevent short circuit failures. Further, since a thin film material having a thickness of 0.03 to 0.3 mm is used as the material of the slot cell 5, even if it is mounted on the side surface portion of the core 2, the size of the core 2 is little affected. The side surface portion of the core 2 to which the slot cell 5 is attached is formed in the same shape and size as the side surface portion of the insulator 4 that abuts.

As shown in FIG. 1, the coil 6 is wound in the winding region 36 so as to contact the body portion 4 a of the insulator 4 and the slot cell 5 so as to cover the core 2. In the stator according to the first embodiment, the coil 6 is formed of the copper wire on which the insulating coating is formed, but the material may be selected within the industrially applicable range such as the aluminum wire.

FIG. 5 shows a rotary electric machine 16 using the stator according to the first embodiment. FIG. 5A is a perspective view of the rotary electric machine 16. FIG. 5B shows a cross section taken along the line CC of FIG. FIG. 5C is a diagram showing a stator 12 obtained by assembling the 12 magnetic poles 1 shown in FIG. 1 into an annular shape. The stator 6 is obtained by connecting the coils 6 of the respective magnetic poles in the stator 12 and, for example, by shrink-fitting or press-fitting the aluminum frame 25 on the outer peripheral portion of the stator 12. Here, the stator may be held by using an iron frame instead of the aluminum frame or a resin frame formed by resin so as to be integrally sealed with the stator 12. The rotating electric machine 16 is obtained by inserting the rotor 14 into the inner diameter portion of the stator assembly 13 and connecting the stator assembly 13 and the rotor 14 with the bracket 15 containing the bearing. The stator according to the present invention has a structure with 12 magnetic poles, but the number of magnetic poles is not limited to this. The stator is obtained by assembling a plurality of magnetic poles in an annular shape.

FIG. 6 is a diagram showing a method of manufacturing the magnetic pole 1 in the stator 12 according to the present invention. In the method for manufacturing the magnetic pole 1, a step of stamping and forming the core sheets 3 of the number of laminated sheets from the magnetic material 100, a step of press-molding the protrusion 10 on one of the core sheets of the number of laminated sheets, and a step of punching and forming. And a step of discharging the core sheet 3 and the core sheet 3a (or the core sheet 3b) manufactured by repeating the step of press molding from the press machine 33 to the aligning and conveying section, and the cutout section 20 in the gap between the core sheets by the protrusions 10. And cutting out the core sheet bundle 18 for every number of stacked sheets, assembling the slot cells 5 on both side surfaces of the core sheet bundle 18 in the stacking direction, and on the end surface of the core sheet bundle 18 in the stacking direction. A step of fitting the holes 10 of the insulator 4 in alignment with the protrusions 10, a step of winding a coil around a core sheet bundle in which the slot cells and the insulator are assembled to form a magnetic pole, and a plurality of magnetic poles are circled. Assembling in a ring shape.

The respective steps are shown in FIGS. 6A to 6G.
FIG. 6A is a diagram showing a step of punching and molding the core sheet 3. For example, the core sheet 3 is obtained by punching out a sheet-shaped magnetic material 100 such as an electromagnetic steel plate.
FIG.6(b) is a figure which shows the process of press-molding the core sheet with a protrusion. When the core sheet 3 is press-molded, it is necessary to periodically control the press-molding timing of the protrusions 10 on the press machine 33 side (controlling the punching in and out of the mold by a programmable logic controller (PLC)). The protrusion 10 is formed in the first stage 31 and the core sheet 3a (or the core sheet 3b) is press-molded in the second stage 32 for each number of laminated cores 2. For example, when the thickness of the electromagnetic steel sheet is 0.5 mm and the laminated thickness of the core 2 is 50 mm, 99 core sheets 3 having no protrusions 10 are punched out, and then the core sheet 3a (or the core sheet 3b) having the protrusions 10 is formed. By punching out one sheet, a core 2 as shown in FIG. 2 in which a protrusion 10 is formed on one of the two end faces in the stacking direction is obtained.

FIG. 7 shows a method of manufacturing the protrusion 10. As shown in FIG. 7, the protrusions 10 are formed by using the magnetic material 100 such as an electromagnetic steel plate and the like by half punching (not punching) with the punch 26 of the mold, and the core of the end face in the stacking direction of the core 2 is formed. The sheet 3a is produced. By punching the punch 26 in and out of the upper die on the first stage 31 for forming protrusions with an air cylinder or the like, it is possible to control whether or not half punching is performed and to control the protrusions 10 for each predetermined number of laminated cores 2. Can be controlled.
FIG. 6C is a diagram showing a process of discharging the punched core sheets 3 and 3 a from the press machine 33. The punched laminated sheets, the core sheet 3 and the core sheet 3a, are continuously ejected from the press machine 33, and are thus arranged so as to be adjacent to each other in the laminating direction from the protrusions 10 on the core sheet 3a via the alignment conveyance unit 17. The core sheet group (hereinafter referred to as core sheet bundle 18) is discharged to the outside of the press machine 33. Here, the aligning and conveying unit 17 uses, for example, a pipe shooter having a conveying rail 17a.

FIG. 6D is a diagram showing a process of cutting out the core sheet bundle 18 corresponding to the laminated thickness of the core 2 from the discharged core sheet bundle 18. Since the protrusions 10 are press-molded for each predetermined number of laminated sheets, the core sheet bundle 18 has a predetermined gap, that is, a gap 19 is formed for each laminated thickness of the cores 2. The distance of the gap 19 in the stacking direction corresponds to the height of the protrusion 10 (0.2 to 1 mm). For example, the core sheet bundle 18 of the number of core sheets 3 corresponding to the laminated thickness of the core 2 is cut out by moving in the stacking direction with the cutout portion 20 which is a thin plate-shaped tool inserted in the gap 19. You can By repeating this operation, a plurality of cores 2 can be obtained.
Here, the aligning and conveying section 17 shown in FIGS. 6A to 6D is shown as a pipe shooter having two conveying rails 17a for convenience, but as shown in FIG. A pipe shooter having two transport rails 17a in FIG. 8A, three transport rails 17a in FIG. 8B, and four transport rails 17a in FIG. 8C can be similarly transported. An apparatus other than a pipe shooter that can align and convey core sheets may be used. The core sheet shown in FIG. 8 is a diagram schematically showing the core sheet 3a having the protrusions 10, but the core sheet 3 having no protrusions can be similarly aligned and conveyed.

FIG. 6E is a diagram showing a step of attaching the insulator 4 to the cut out core 2 and a step of attaching the slot cell 5. After mounting the two slot cells 5 on both side surface portions 2a of the core 2, the two insulators 4 are mounted on both end surfaces of the core 2 in the stacking direction. In the first embodiment, the protrusion 10 is fitted into the hole 11 of the insulator 4 on the end surface of the core 2 having the protrusion 10. Similarly, when both ends of the core 2 in the stacking direction have the protrusions 10, the insulators 4 each having the hole 11 are fitted.
FIG. 6F is a diagram showing a process of winding the core 4 on which the insulator 4 and the slot cell 5 are installed. A coil 6 is formed by winding a copper wire 6a having an insulating coating formed thereon from above the insulator 4 and the slot cell 5 so as to cover the core 2.
Further, the protrusions 10 may be formed on the core sheets on both end surfaces of the core 2 in the stacking direction. In this case, the manufacturing method is the same, and the core sheets on both end faces also have protrusions between the bundles of core sheets, and the interval between the core sheet bundles is wider than when there is a protrusion on one end face.

FIG. 6(g) shows a process of obtaining the stator 12 by connecting 12 magnetic poles 1 and, for example, performing a necessary coil connection and assembling them in an annular shape.
The stator 12 according to the first embodiment can be obtained by the manufacturing method including the steps shown in FIGS. 6A to 6G.

According to the stator and the rotating electric machine using the stator according to the first embodiment, the core sheets 3 forming the core 2 are not fixed by punching or welding, and the core sheets are electrically connected to each other. Therefore, the eddy current loss is suppressed and a highly efficient rotating electrical machine can be obtained.
Further, the side surfaces of the stacked cores are aligned and mounted by the slot cells, and the protrusions 10 provided on the core 2 and the holes 11 provided on the insulator 4 are fitted together, so that the insulator 4 is mounted on the core 2. Can be installed with high position accuracy. Since it is possible to suppress the positional deviation and the floating of the insulator 4 (the contact surface between the core 2 and the insulator 4 separates) due to the tension applied to the copper wire during the winding, the disturbance accompanied by the change in the trace of the copper wire during the winding ( (Disturbance of winding) is suppressed, and the copper wire can be wound more densely. The output density of the rotary electric machine 16 can be improved by winding more copper wires around the finite winding region 36.

According to the manufacturing method of the stator according to the first embodiment, in the manufacturing process, in the core sheet bundle 18 discharged to the outside of the press machine 33 through the aligning and conveying unit 17, every predetermined number of laminated sheets, that is, the lamination of the cores 2. Since the cutout portion 20 can be simply cut out for each thickness, the number of steps can be reduced. In addition, by controlling the press molding timing of the protrusion 10 on the press machine 33 side (controlling the punch punch of the die by a programmable logic controller (PLC) or the like), the laminated thickness of the core 2 to be cut can be easily adjusted, Model setup is simplified and productivity is improved.
When the protrusion 10 is formed by press molding and the hole 11 is formed by injection molding, the dimensions such as position and height can be managed with high accuracy of about ±0.01 mm, so that the fitting state can be easily adjusted and productivity can be improved. It can lead to improvement.

As described above, according to the stator according to the first embodiment and the rotary electric machine using this stator, the output density and the output efficiency can be improved. Further, according to the stator manufacturing method of the first embodiment, productivity can be improved.

Embodiment 2.
FIG. 9 is a perspective view of a connecting magnetic pole 21 in which three magnetic pole teeth constituting the stator 12 according to the second embodiment are connected. FIG. 10 shows a plan view of the core sheet 23 connected on the outer peripheral side of the yoke portions for three poles. FIG. 10A is a plan view of the core sheet 23 having no protrusion 10 connected to three poles, and FIG. 10B is a plan view of the core sheet 23a having the protrusion 10 connected to three poles.
In the second embodiment, the coupling magnetic pole 21 has three magnetic pole teeth connected to three poles, while the core 2 is formed by laminating a plurality of core sheets 3 each having one magnetic pole tooth in the first embodiment. The core 22 has a plurality of laminated core sheets 23. As shown in FIG. 9, the core sheet 23 has a yoke portion 27, a tooth portion 28, and a shoe portion 29 for each magnetic pole, and a thin connecting portion 30 is formed on the outer peripheral side of the yoke portion 27. Since the adjacent magnetic pole teeth are assembled in an annular shape to obtain the stator 12, the thickness of the thin connecting portion 30 in the radial direction is made thinner than the other portions of the core sheet 23.

In the stator 12 according to the second embodiment, as shown in FIG. 9, the configurations of the portion other than the core 22, the insulator 4, the slot cell 5, and the coil 6 are the same as those of the first embodiment. In the stacking direction of the core 22, each magnetic pole has one or more protrusions 10 (shown in FIG. 10B) on either one or both of the upper and lower end faces. Further, the insulators 4 are installed on the upper and lower end surfaces of the magnetic pole of the core 22 in the stacking direction. The insulator 4 has a hole 11 (not shown) into which the protrusion 10 of each magnetic pole on the end surface of the core 22 that abuts is fitted. In addition, for each magnetic pole, a slot cell that covers the circumferential side surface 28a of the tooth portion 28, the inner peripheral surface 27a of the yoke portion 27 adjacent to the side surface 28a and the outer peripheral surface 29a of the shoe portion 29, and the upper and lower end surfaces thereof contact the insulator 4. 5 (not shown), and a coil 6 wound so as to cover the insulator 4 and the slot cell 5 (not shown).

The stator 12 is obtained in the same manner as in the first embodiment by assembling four connecting magnetic poles 21 shown in FIG. 9 into an annular shape, but the number of connected magnetic pole teeth may be two poles, four poles, or six poles. It may be configured from a core sheet in which all 12 poles are connected by the thin connecting portion 30. Also, a combination of 2 poles and 4 poles, a combination of 3 poles and 6 poles, and the like may be used. That is, in the stator 12 including the 12 magnetic poles according to the first embodiment and the second embodiment, 12 poles may be configured by combining the magnetic poles that are not coupled or the coupled magnetic poles that are coupled. A rotary electric machine using the stator according to the second embodiment also has the same structure as that of the first embodiment.
Further, as a modified example of the second embodiment, as shown in FIG. 11, a stator 24 configured by connecting all 12 magnetic poles may be used. In this case, the connecting stator forms an annular shape, and when assembling the rotating electric machine, the work of assembling in an annular shape is unnecessary. The stator 24 is similar in appearance and use to the stator 12.

Next, a description will be given of the coupling magnetic pole 21 and the method of manufacturing the stator 12 using the coupling magnetic pole 21 in the second embodiment. It is the same as the reference numeral in the step shown in FIG. The description of the same parts as those in the first embodiment will be omitted.
In the case of the connecting magnetic pole 21, first, the core sheet 23 to be connected is stamped and formed.
After that, after the required number of laminated cores are overlapped and formed, the core sheet 23a having the protrusions 10 is press formed.
The core sheet 23 having no protrusion to be connected and the core sheet 23a having a protrusion, which are manufactured by repeating the step of punching and the step of press-forming, are discharged from the press machine to the aligning and conveying section 17. For example, FIG. 12 shows an image in which the core sheet 23a is aligned and conveyed by the aligning and conveying unit 17 having two conveying rails 17b for each magnetic pole. Although the core sheet shown in FIG. 12 is an image of the core sheet 23a having a protrusion, the core sheet 23 having no protrusion can be aligned and conveyed in the same manner.
Next, the cutout portion 20 is inserted into the gap 19 between the core sheets formed by the protrusions 10, and the stacked core sheet bundle is cut out.
Then, two slot cells 5 are assembled for each magnetic pole, two insulators 4 are assembled for each magnetic pole, and then a coil is wound for each magnetic pole.
Finally, the stator 12 can be manufactured by connecting the coils of the respective magnetic poles and assembling them in an annular shape using the necessary magnetic poles.
Even in the case of the stator 24 constituted by the 12-pole annular core sheet, the work of assembling in an annular shape is not necessary, and the stator 24 can be similarly manufactured. In this case, 24 slot cells 5 are assembled for each magnetic pole, and 24 insulators 4 are assembled for each magnetic pole.

The stator according to the second embodiment and the rotating electric machine using the stator have the same effects as those of the first embodiment, and the output density and efficiency can be improved. Regarding the effect of the stator manufacturing method according to the second embodiment, productivity can be improved as in the first embodiment, and the number of parts is smaller than that in the first embodiment, so that member management is simplified. The cost will be lower.

1 magnetic pole, 2 core, 3a, 3b core sheet, 4 insulator, 4a body, 4b first flange, 4c second flange, 4d abutting surface of insulator 4, 5 slot cell, 6 coil, 6a copper wire, 7 yoke part, 8 teeth part, 9 shoe part, 7a inner peripheral surface, 8a side surface, 9a outer peripheral surface, 10 protrusion, 11 hole part, 12 stator, 13 stator assembly, 14 rotor, 15 bracket, 16 rotating electric machine 17 Aligning and Conveying Section, 17a, 17b Conveying Rail, 18 Core Sheet Bundle, 19 Gap, 20 Cutout Section, 21 Connecting Magnetic Pole, 22 Core, 23, 23a Core Sheet, 24 Stator, 25 Aluminum Frame, 26 Punch, 27, Yoke Part, 28 teeth part, 29 shoe part, 27a inner peripheral surface, 28a side surface, 29a outer peripheral surface, 30 thin connection part, 31 first stage, 32 second stage, 36 winding region

Claims (7)

A thin plate including a plurality of annularly arranged yoke portions extending in the circumferential direction, teeth portions extending in the radial direction from the yoke portions, and shoe portions extending in an arc shape in the circumferential direction at the tips of the teeth portions. A plurality of core-shaped core sheets are laminated, and a core having protrusions on either or both end faces of the upper and lower end faces in the laminating direction,
An insulator having a hole portion that is installed on the end face and that is fitted to the protrusion,
A slot cell that covers both side surfaces in the circumferential direction of the core, and abuts on the insulator on the end surface side,
A coil wound around the insulator and the slot cell,
A stator of a rotating electric machine including. The stator of a rotary electric machine according to claim 1, wherein a plurality of the protrusions are provided on the end surface. The stator of a rotary electric machine according to claim 1, wherein the protrusion has a rectangular shape, and one protrusion is provided on the end surface. The stator of the rotating electric machine according to claim 1, wherein the slot cell covers a side surface of the tooth portion, an inner peripheral surface of the yoke portion adjacent to the side surface, and an outer peripheral surface of the shoe portion. .. The stator of a rotary electric machine according to claim 1, further comprising a core connected on an outer peripheral side of the yoke portion. A stator according to any one of claims 1 to 5,
A frame for holding the stator,
A rotor disposed in the inner diameter portion of the stator,
Rotating electric machine. A step of punching and molding a plurality of core sheets from a magnetic material,
A step of press-molding a protrusion on one of the plurality of core sheets;
A step of discharging the core sheet produced by repeating the step of punching and the step of press-forming from a press machine to an aligning and conveying section;
A step of inserting a cutout portion into a gap generated by the protrusion between the core sheets to cut out a core sheet bundle;
A step of assembling the slot cells on both side surfaces in the stacking direction of the core sheet bundle;
A step of fitting the hole portion of the insulator to the end face in the stacking direction of the core sheet bundle in accordance with the protrusion,
A step of winding a coil around the core sheet bundle in which the slot cells and the insulator are assembled to form a magnetic pole;
A step of assembling the plurality of magnetic poles into an annular shape,
A method for manufacturing a stator of a rotating electric machine, including:

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