JP4027132B2

JP4027132B2 - Iron core device, method for manufacturing iron core device, permanent magnet motor and hermetic compressor

Info

Publication number: JP4027132B2
Application number: JP2002077206A
Authority: JP
Inventors: 智明及川; 浩二増本; 庸賀田島; 修風間
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2002-03-19
Filing date: 2002-03-19
Publication date: 2007-12-26
Anticipated expiration: 2022-03-19
Also published as: JP2003284268A

Description

【０００１】
【発明の属する技術分野】
この発明は圧縮機等に用いられる電動機に関するもので、詳しくは固定子鉄心の構成に関するものである。
【０００２】
【従来の技術】
出願人は特開２０００−２０１４５８号公報で、板状の第１コア片を複数個連続的に配列する第１コア部材と、板状の第２コア片を複数個連続的に配列する第２コア部材とが、積層方向に所定枚数毎交互に、第１コア部材の各第１コア片間位置と第２コア部材の各第２コア片間位置とが長手方向にずれて、各コア片の積層方向に相隣る縁部同士が重なり合うように積層され、相隣る各コア片の縁部同士を連結する連結手段が設けられ、磁極ティースに巻線を施した後連結手段で各コア片を回動させることにより環状又は矩形状に形成された電動機鉄心を製造することを提案している。
【０００３】
図１０は第１コア部材と第２コア部材を一枚毎交互に積層した場合の断面図である。図において、４は第１コア部材、５は第２コア部材、５１は積層コアの最上層となる第３コア部材である。このように構成することにより、各コア片の積層方向に相隣る縁部同士が重なるように積層されているので、打ち抜かれた各コア片の端面が重なり合わされた寸法だけ交互にずれて分断され（つまり各コア片の端面が連続しないので）、同一平面内に存在する部分の面積が小さくなるため、渦電流の発生を抑制して鉄損を減少させ磁気性能の向上を図ることができる。
【０００４】
図１１は第１コア部材と第２コア部材を二枚毎交互に積層した場合の断面図である。複数枚づつ交互に重ね合わせると、各コア片を連結手段（例えば、凸部及び凹部）で回動するとき、複数枚づつの枚数が多くなるほど、摩擦が減少し、生産性が向上する。
【０００５】
【発明が解決しようとする課題】
従来の電動機は以上のように構成されており、第１コア部材４と第２コア部材５の重なりあわせを一枚毎交互にする構成をとる場合は、各コア片を連結手段（例えば、凸部及び凹部）で回動するときの、第１コア部材４と第２コア部材５の摩擦が大きく、特に積層厚さが多い場合や、板厚の薄いコア部材としたため積層枚数が多い場合に回動させるための力が大きく必要となり、生産性が悪化するという問題点があった。
【０００６】
又、第１コア部材４と第２コア部材５の重なりあわせを複数枚づつ交互にした構成とした場合は、摩擦の問題は少なくなるものの、積層厚さの微調整がしにくくなる問題がある。電動機鉄心の積層厚さは、鉄心プレス機においてコア材料の厚みを考慮し、コア部材積層枚数を指令値として制御されるのが一般的である。しかしながら、コア材料の厚みがロット内でばらつき変化した場合、鉄心の積厚ばらつきを発生させる。このばらつきが管理許容値を超えた場合、積層端部にあたるコア部材をはがして、積層厚みの微調整を行うことがあるが、この時、一枚毎の重なり合わせならば、一枚毎コア部材をはがし積厚調整ができるものの、複数枚毎交互重なりあわせの場合は、コア部材をはがす際に複数枚まとめてはがれてしまい、微調整が難しいという問題点があった。
【０００７】
この発明は、上記のような問題点を解決するためになされたもので、製造時のコア回動力の低減と積厚の微調整が可能な電動機を提供することを目的とする。
【０００８】
【課題を解決するための手段】
この発明に係る鉄心装置は、板状の第１コア片を複数個連続的に配列する第１コア部材と、板状の第２コア片を複数個連続的に配列する第２コア部材とを、積層方向に交互に、第１コア部材の各第１コア片間位置と第２コア部材の各第２コア片間位置とが長手方向にずれて、前記各コア片の積層方向に相隣る縁部同士が重なり合うように積層され、相隣る各コア片の縁部同士を連結する連結手段が設けられ、連結手段で各コア片を回動させることにより環状又は矩形状に形成された鉄心装置において、一枚もしくは複数枚毎交互に重ね合わせられる第一コア部材と第２コア部材のそれぞれの積層方向の重なり合わせを、積層中央部よりも積層端部において少ない枚数毎としたことを特徴とする。
【０００９】
また、この発明に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、積層端部は一枚毎交互に重なり合うようにしたことを特徴とする。
【００１１】
また、この発明に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部よりも、透孔が設けられる積層端部とは逆側の積層端部において少ない枚数毎としたことを特徴とする。
【００１２】
また、この発明に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、透孔が設けられる積層端部とは逆側の積層端部は一枚毎交互に重なり合うようにしたことを特徴とする。
【００１４】
また、この発明に係る鉄心装置は、連結手段は、第１コア部材の第１コア片の一端側縁部表裏面と、第２コア部材の第２コア片の他端側縁部表裏面にそれぞれ形成され、コア片の積層方向に相隣る縁部同士が嵌合可能な凹部および凸部で構成されていることを特徴とする。
【００１５】
また、この発明に係る鉄心装置は、連結手段は、ピン部材を用いたピン接続としたことを特徴とする。
【００１６】
また、この発明に係る鉄心装置は、連結手段は、バックヨークの薄肉部を折り曲げるものとしたことを特徴とする。
【００１７】
この発明に係る永久磁石形電動機は、請求項１〜７の何れかに記載の鉄心装置と、永久磁石を設けた回転子とを備えたことを特徴とする。
【００１８】
この発明に係る密閉形圧縮機は、請求項８に記載の永久磁石形電動機を用いたことを特徴とする。
【００１９】
この発明に係る鉄心装置の製造方法は、板状の第１コア片を複数個連続的に配列する第１コア部材と、板状の第２コア片を複数個連続的に配列する第２コア部材とを、積層方向に交互に、かつ各コア部材の積層方向の重なり合わせを、積層中央部よりも積層端部において少ない枚数毎に、第１コア部材の各第１コア片間位置と第２コア部材の各第２コア片間位置とが長手方向にずれて、各コア片の積層方向に相隣る縁部同士が重なり合うように積層する工程と、相隣る各コア片の縁部同士を連結する連結手段を設ける工程と、連結手段で各コア片を回動させることにより環状又は矩形状に形成する工程とを備えたことを特徴とする。
【００２０】
また、この発明に係る鉄心装置の製造方法は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、積層端部は一枚毎交互に重なり合うようにしたことを特徴とする。
【００２８】
また、この発明に係る鉄心装置の製造方法は、コア部材逆反り状態で巻線を施したされた後、連結手段で各コア片を回動させることにより環状又は矩形状に形成することを特徴とする。
【００２９】
また、この発明に係る鉄心装置の製造方法は、コア片の縁部の凸部および凹部が形成され、積層コアのかしめ結合用凹凸部がコア片の中央部に形成される第１の工程と、第１の工程で凹凸部が形成された周辺部分に、第１コア部材を加工する第２段階として、両端面及び両端面の周辺部を形成する第２の工程と、第１の工程で凹凸部が形成された周辺部分に、第２コア部材を加工する第２段階として、両端面及び両端面の周辺部を形成する第３の工程と、第２の工程と第３の工程で両端面が形成された部分を、順次交互にプレス打ち抜きすることにより、それぞれ第１コア部材、第２コア部材が形成され、これらの第１コア部材、第２コア部材は金型内で順次積層される第４の工程と、とを備え、第１コア部材と第２コア部材をそれぞれ複数枚ずつ交互に積層し、それぞれの積層方向の重なり合わせを、積層中央部よりも、積層端部において少ない枚数毎とする場合、第２の工程と第３の工程のプレス打抜きの間欠動作をそれぞれ重なり合わせ枚数毎複数回毎交互に行うことを特徴とする。
また、この発明に係る鉄心装置の製造方法は、コアの積層厚を測定し、指定寸法値よりも厚い場合には、コア枚数を１枚、もしくは複数枚剥がして積層厚を調整する工程を設けたことを特徴とする。
【００３０】
【発明の実施の形態】
実施の形態１．
以下、この発明の実施の形態の一例を図面に基づいて説明する。
図１〜９は実施の形態１を示す図で、図１は鉄心装置の構成を示す平面図、図２は図１に示すコア部材をプレス打ち抜きにより形成する工程を示す平面図、図３は図２に示す工程を経て形成されたコア部材の連結手段の構成を示す断面図、図４は図２に示す工程を経て形成されたコア部材が積層された状態を示す平面図、図５は図４に示すように積層されたコア部材の各コア片の縁部の構成を示す断面図、図６は巻線時のコア部材の姿勢を示す平面図、図７はコア部材の他の連結手段を示す構成図、図８はコア部材のさらに他の連結手段を示す構成図、図９は永久磁石形電動機の縦断面図である。
【００３１】
図において、３は磁性材料でなる板状のコア片で、一端側縁部表裏面に連結手段としての凸部３ｂおよび凹部３ａが形成されると共に、その端面３ｃはこれら凸部３ｂおよび凹部３ａの中心を中心とした凸円弧状に形成され、他端側には相隣るコア片３の端面３ｃと嵌合可能な凹円弧状の端面３ｄが形成されている。
【００３２】
図２に示すように、４は複数のコア片３が各端面３ｃ、３ｄを介して連続的に配列された第１コア部材である。５は複数のコア片３が各端面３ｃ、３ｄを介して連続的に配列された第２コア部材である。第１コア部材４のコア片３は一端側縁部表裏面に連結手段（すなわち連結機構）としての凸部３ｂおよび凹部３ａが形成されており、第２コア部材５のコア片３は他端側縁部表裏面に連結手段（すなわち連結機構）としての凸部３ｂおよび凹部３ａが形成されている。
【００３３】
図３〜５に示すように、第１コア部材４と第２コア部材５は交互に積層され、第１コア部材４の各コア片間位置（すなわち各コア片端面３ｃ、３ｄ間位置）と第２コア部材５の各コア片間位置（すなわち各コア片端面３ｃ、３ｄ間位置）とが長手方向にずれて、各コア片の積層方向に相隣る縁部同士が重なり合うように積層されている。そして積層方向に相隣るコア片３の縁部同士において、第１コア部材４のコア片３の一端側縁部の凸部３ｂおよび凹部３ａと、第２コア部材５のコア片３の他端側縁部の凸部３ｂおよび凹部３ａとが嵌合されることにより回動自在に連結されている。
【００３４】
この時、図５に示すように、第１コア部材４と第２コア部材５は積層方向中央部２２では、複数枚毎に交互に積層され、積層端部２０、２１では１枚毎交互に積層されている。図５では積層中央部２２において２枚ずつ交互に重ねわせているが、後述する特性が許す限り複数枚（例えば、２〜１０枚づつ）を交互に重ね合わせても良い。複数枚づつ交互に重ね合わせると、各コア片３を連結手段（例えば、凸部３ｂ及び凹部３ａ）で回動するとき、複数枚づつの枚数が多くなるほど、摩擦が減少し、生産性が向上する。
【００３５】
しかし、一方、枚数が多くなればなるほど、プレスで打ち抜かれた端面３ｃ、３ｄが同一平面内に存在し、この端面には絶縁皮膜が存在しないため、積層方向に渦電流が発生しやすくなり、この渦電流により鉄損を生じ磁気性能を低下させるという問題点がある。
【００３６】
また、第１コア部材４のコア片３の一端側縁部の凸部３ｂおよび凹部３ａと、第２コア部材５のコア片３の他端側縁部の凸部３ｂおよび凹部３ａとの嵌合により持たせていた機械的強度が低下するといった問題が生じる。
【００３７】
すなわち、複数枚毎の積層枚数は摩擦力低減による生産性と、磁気性能と、機械的強度を考慮して決定される値である。また、積層端部２０、２１においては、第１コア部材４と第２コア部材５の重なり合わせを積層中央部２２に対し少ない枚数毎としている（図では一枚毎）。この時、積層端部２０、２１の長さは積層中央部２２の長さに対し充分短いものになっており、回動時の摩擦力による生産性、磁気性能、機械強度においてはおおよそ積層中央部２２の特性となるようにされている。
【００３８】
電動機鉄心の積層厚さは、鉄心プレス機においてコア材料の厚みを考慮し、コア部材積層枚数を指令値として制御されるのが一般的である。しかしながら、コア材料の厚みがロット内でばらつき変化した場合、鉄心の積厚ばらつきを発生させる。このばらつきが管理許容値を超えた場合、積層端部２０、２１にあたるコア部材をはがして、積層厚みの微調整を行うことがあるが、この時、一枚毎の重なり合わせならば、一枚毎コア部材をはがし積厚調整ができるものの、複数枚毎交互重なりあわせの場合は、コア部材をはがす際に複数枚まとめてはがれてしまい微調整が難しいという問題点がある。
【００３９】
しかしながら、本発明によればコア部材をはがすことにより厚みを調整される積厚端部２０、２１は、１枚毎もしくは必要最小枚毎の重ね合わせになっているため、生産性向上のため積厚中央部２２を複数枚ラップとしても、鉄心積厚の微調整ができるものとなっている。また、積層端部は、鉄心上部、下部両側であっても良いし、片側でも良い。
【００４０】
通常積層端部２０には、図３に示すように透孔３ｅが設けられ、コア片３の縁部の凸部３ｂ及びコア片３の中央部に配置されるかしめ結合用凸部３ｇと嵌合される。この透孔３ｅは連続的に積層されるプレス機金型内にて、所望の厚みに鉄心積層厚みを調整するとともに、凸部が鉄心から出ないように設けられる。このため、鉄心積厚の微調整は透孔３ｅとは逆側の積層端部２１をはがすことによって調整される。つまり、この意味においては積層端部の１枚毎もしくは必要最小枚毎の重ね合わせは、少なくとも透孔３ｅとは逆側の積層端部２１のみにあれば良いことになる。
【００４１】
また、図１の６は各コア片３の磁極ティース３ｆ（図４）にそれぞれ巻回された巻線、７は積層された両コア部材４、５の各コア片３の凹、凸部３ａ、３ｂを回動させることによって環状に形成された鉄心装置である。なお、図１で、第１コア部材４と第２コア部材５とを積層した積層コアの端部同士（環状体の繋ぎ目）においては、端部同士を当接結合させるために、連結手段（凸部３ｂおよび凹部３ａ）が、省略されている。
【００４２】
次に、上記のように構成された実施の形態１における鉄心装置の製造方法について説明する。まず、図２に矢印Ｔで示す位置において、コア部材の表裏面に圧入嵌合可能な凸部および凹部が、各コア片につき３箇所プレス打ち抜き動作によって形成される。この第１段階で、図３に示すように、コア片３の縁部の凸部３ｂおよび凹部３ａが形成され、積層コアのかしめ結合用凹凸部がコア片３の中央部に形成される（図では２個）。
【００４３】
矢印Ａで示す位置において、矢印Ｔの段階で凹凸部が形成された周辺部分に、第１コア部材４を加工する第２段階として、図中ハッチングで示す部分をプレス打ち抜きすることにより両端面３ｃ、３ｄ及び両端面３ｃ、３ｄの周辺部を形成する。又、矢印Ｂで示す位置においては、矢印Ｔの段階で凹凸部が形成された周辺部分に、第２コア部材５を加工する第２段階として、図中ハッチングで示す部分をプレス打ち抜きすることにより両端面３ｃ、３ｄ及び両端面３ｃ、３ｄの周辺部を形成する。
【００４４】
次いで、図２に矢印Ｃで示す位置において、矢印Ａの段階で両端面３ｃ、３ｄが形成された部分と、矢印Ｂの段階で両端面３ｃ、３ｄが形成された部分を、順次交互に図中ハッチングで示す部分をプレス打ち抜きすることにより、それぞれ第１コア部材４、第２コア部材５が形成され、これらの第１コア部材４、第２コア部材５は金型内で順次積層される。
【００４５】
矢印Ａ部と矢印Ｂ部のプレス打抜きは間欠動作ができるようになっており、矢印Ａの位置でプレス打ち抜きされた第１コア部材４は、コア部材が金型内で順送りされ、矢印Ｂの位置では打ち抜きをせずに順送りされ、矢印Ｃで示す位置にて図中ハッチングで示す部分をプレス打ち抜きする。第１コア部材４と第２コア部材５を交互に積層する場合は、次に、矢印Ａの位置では打ち抜きをせずに順送りされ、矢印Ｂの位置でプレス打ち抜きされた第２コア部材５を矢印Ｃで示す位置にて図中ハッチングで示す部分をプレス打ち抜きするのと同時に、先に打ち抜かれた第１コア部材４にカシメられ積層される。これを順次繰り返すことにより第１コア部材４と第２コア部材５が交互に積層される。
【００４６】
第１コア部材４と第２コア部材５をそれぞれ２枚ずつ交互に積層する場合には、矢印Ａ部と矢印Ｂ部のプレス打抜きの間欠動作をそれぞれ２回毎交互に行い、「矢印Ａ部で打ち抜き−矢印Ｂ部は打ち抜かず順送り−矢印Ｃ部で打ち抜き」を２回連続して行ったあと、「矢印A部は打ち抜かず順送り−矢印Ｂ部で打ち抜き−矢印Ｃ部で打ち抜き」を２回連続して行う。これを繰り返すことによって第１コア部材４と第２コア部材５が２枚毎交互に重なりあうようになる。このように、プレス打抜きの間欠動作によって、自由に複数枚毎の重なり合わせが可能となる。間欠動作を鉄心積層端部と積層中央部で変化させれば、重なり合わせ枚数も変化させることができる。
【００４７】
又、矢印Ｓで示す位置において、矢印Ｔの段階で形成する凹凸部と同じ位置に各コア片につき３箇所の透孔がプレス打ち抜き動作によって形成される。これにより、積層コアの最上層となるコア片３に、凸部３ｂが嵌合可能な３箇所の透孔３ｅが形成される。矢印Ｂで示す位置において、矢印Ｓの段階で透孔３ｅが形成された部分に、第３コア部材５１を加工する第２段階として、図中ハッチングで示す部分をプレス打ち抜きすることにより両端面３ｃ、３ｄ及び両端面３ｃ、３ｄの周辺部を形成する。矢印Ｃで示す位置において、矢印Ｂの段階で両端面３ｃ、３ｄが形成された部分に図中ハッチングで示す部分をプレス打ち抜きすることにより、第３コア部材５１が形成され、積層コアの最上層として、金型内に積層される。
【００４８】
例えば、積層厚みを７５ｍｍにしたい場合には、コア材料の厚みを０．３５ｍｍとした時、コア片の積層枚数は約２１４枚であり、２１４枚目に透孔３ｅ付きのコア片とすれば、所望の積層積厚を得ることができる。
【００４９】
なお、図２において、第１コア部材４や第２コア部材５の両端のコア片３は、中央のコア片３と縁部において一部不揃いである。これは、両端のコア片３が第１コア部材４と第２コア部材５とを積層した積層コアの端部同士にあたり、端部同士を当接結合させ易くするためである。以下、積層コアの両端のコア片が、中央のコア片と一部不揃いであるのは、このためである。
【００５０】
金型内で各コア片３の積層方向で相対向する凹部３ａおよび凸部３ｂ、透孔３ｅおよび凸部３ｂ同士が圧入嵌合されるとともに、抜きかしめがなされ図４に示すように一体化される。そして、積層されたコア部材４、５および５１の各コア片３の磁極ティース３ｆには、図４に示すようにコア部材直線展開状態もしくは、図６で示すようなコア部材逆反り状態で巻線６（図示せず）が施された後、嵌合された凹部３ａおよび凸部３ｂ、透孔３ｅおよび凸部３ｂを回動させることにより環状に形成して鉄心装置７が完成する。
【００５１】
図４はコア片３を直線状に配列させた場合であるが、図６のように逆反り状態にして、巻線を施せばさらに巻線工作性が改善される。
【００５２】
上記製造方法においては、コア部材の打ち抜きはコア片を直線状に配置している例を上げているが、コア片を最終電動機鉄心形状の円環状に配置するように打ち抜いても良い。電動機鉄心としての最終形状にて予めプレス打ち抜きをし、その後コア片を展開して巻線をし、打ち抜き状態の円環状に戻せば、より精度のよい電動機を得ることができる。
【００５３】
また、本実施の形態では、縁部同士を連結する連結手段として、嵌合可能な凹部および凸部にての例を示しているが、連結手段としては、図７のようにピン部材１７を用いたピン接続のものでも良いし、図８のようにバックヨークの薄肉部２３を折り曲げるタイプのものでも同様の効果を得ることができるが、コア片に凹部、凸部をつけた本実施の形態のものが最も精度、生産上有効である。
【００５４】
また、回転子として永久磁石を用いた電動機、例えばブラシレスＤＣモータなどの場合には次のような効果も期待できる。図９は永久磁石型電動機の縦断面図であるが、永久磁石型電動機は固定子２４よりも回転子２５の方が積厚が厚いのが一般的である。これは、永久磁石２６の磁力を有効に使用するためで、固定子よりオーバーハングした回転子の永久磁石の矢印で示した磁束２８は回転子外周鉄部２７を通り、固定子に回り込む。このため、固定子の磁束密度は積層中央部２２より積層端部２０、２１の方が高く、コア片間の端面３ｃ、３ｄの渦電流が発生しやすくなるが、本発明の形態とすれば、積層端部での重なり合わせ枚数を少ない枚数毎としているため、渦電流の影響を低減でき効率の良い永久磁石形電動機とすることができる。
【００５５】
また、上記永久磁石形電動機を密閉形圧縮機に使用すれば、密閉形圧縮機の性能を向上することができる。
【００５６】
【発明の効果】
この発明の請求項１に係る鉄心装置は、第一コア部材と第２コア部材のそれぞれの積層方向の重なり合わせを、積層中央部よりも積層端部において少ない枚数毎としたことにより、巻線時に巻線しやすいよう積層鉄心を展開するためにコア片を回動する際の力を軽減できると共に、鉄心積層積厚の微調整が容易になる。
【００５７】
また、この発明の請求項２に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、積層端部は一枚毎交互に重なり合うようにしたことにより、巻線時に巻線しやすいよう積層鉄心を展開するためにコア片を回動する際の力を軽減できると共に、鉄心積層積厚の微調整が容易になる。
【００５９】
また、この発明の請求項３に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部よりも、透孔が設けられる積層端部とは逆側の積層端部において少ない枚数毎としたことにより、鉄心積層積厚の微調整を確実に行うことができる。
【００６０】
また、この発明の請求項４に係る鉄心装置は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、透孔が設けられる積層端部とは逆側の積層端部は一枚毎交互に重なり合うようにしたことにより、鉄心積層積厚の微調整を確実に行うことができる。
【００６２】
また、この発明の請求項５に係る鉄心装置は、連結手段は、第１コア部材の第１コア片の一端側縁部表裏面と、第２コア部材の第２コア片の他端側縁部表裏面にそれぞれ形成され、コア片の積層方向に相隣る縁部同士が嵌合可能な凹部および凸部で構成されていることにより、精度が良く、生産性の高い鉄心装置を得ることができる。
【００６３】
また、この発明の請求項６に係る鉄心装置は、連結手段は、ピン部材を用いたピン接続としたことにより、精度が良く、生産性の高い鉄心装置を得ることができる。
【００６４】
また、この発明の請求項７に係る鉄心装置は、連結手段は、バックヨークの薄肉部を折り曲げるものとしたことにより、生産性の高い鉄心装置を得ることができる。
【００６５】
この発明の請求項８に係る永久磁石形電動機は、請求項１〜７の何れかに記載の鉄心装置と、永久磁石を設けた回転子とを備えたことにより、高効率な永久磁石形電動機を得ることができる。
【００６６】
この発明の請求項９に係る密閉形圧縮機は、請求項８に記載の永久磁石形電動機を用いたことにより、高性能の密閉形圧縮機を得ることができる。
【００６７】
この発明の請求項１０に係る鉄心装置の製造方法は、板状の第１コア片を複数個連続的に配列する第１コア部材と、板状の第２コア片を複数個連続的に配列する第２コア部材とを、積層方向に交互に、かつ各コア部材の積層方向の重なり合わせを、積層中央部よりも積層端部において少ない枚数毎に、第１コア部材の各第１コア片間位置と第２コア部材の各第２コア片間位置とが長手方向にずれて、各コア片の積層方向に相隣る縁部同士が重なり合うように積層する工程と、相隣る各コア片の縁部同士を連結する連結手段を設ける工程と、連結手段で各コア片を回動させることにより環状又は矩形状に形成する工程とを備えたことにより、巻線時に巻線しやすいよう積層鉄心を展開するためにコア片を回動する際の力を軽減できると共に、鉄心積層積厚の微調整が容易になる。
【００６８】
また、この発明の請求項１１に係る鉄心装置の製造方法は、第１コア部材と第２コア部材の積層方向の重なり合わせを、積層中央部は複数枚毎とし、積層端部は一枚毎交互に重なり合うようにしたことにより、巻線時に巻線しやすいよう積層鉄心を展開するためにコア片を回動する際の力を軽減できると共に、鉄心積層積厚の微調整が容易になる。
【００７６】
また、この発明の請求項１２に係る鉄心装置の製造方法は、コア部材逆反り状態で巻線を施したされた後、連結手段で各コア片を回動させることにより環状又は矩形状に形成することにより、巻線工作性が改善される。
【００７７】
また、この発明の請求項１３に係る鉄心装置の製造方法は、コア片の縁部の凸部および凹部が形成され、積層コアのかしめ結合用凹凸部がコア片の中央部に形成される第１の工程と、第１の工程で凹凸部が形成された周辺部分に、第１コア部材を加工する第２段階として、両端面及び両端面の周辺部を形成する第２の工程と、第１の工程で凹凸部が形成された周辺部分に、第２コア部材を加工する第２段階として、両端面及び両端面の周辺部を形成する第３の工程と、第２の工程と第３の工程で両端面が形成された部分を、順次交互にプレス打ち抜きすることにより、それぞれ第１コア部材、第２コア部材が形成され、これらの第１コア部材、第２コア部材は金型内で順次積層される第４の工程と、とを備え、第１コア部材と第２コア部材をそれぞれ複数枚ずつ交互に積層し、それぞれの積層方向の重なり合わせを、積層中央部よりも、積層端部において少ない枚数毎とする場合、第２の工程と第３の工程のプレス打抜きの間欠動作をそれぞれ重なり合わせ枚数毎複数回毎交互に行うことにより、自由に複数枚毎の重なり合わせが可能となる。
また、この発明の請求項１４に係る鉄心装置の製造方法は、コアの積層厚を測定し、指定寸法値よりも厚い場合には、コア枚数を１枚、もしくは複数枚剥がして積層厚を調整する工程を設けたことにより、鉄心積厚の微調整ができる。
【図面の簡単な説明】
【図１】実施の形態１を示す図で、鉄心装置の構成を示す平面図である。
【図２】図１に示すコア部材をプレス打ち抜きにより形成する工程を示す平面図である。
【図３】図２に示す工程を経て形成されたコア部材の連結手段の構成を示す断面図である。
【図４】図２に示す工程を経て形成されたコア部材が積層された状態を示す平面図である。
【図５】図４に示すように積層されたコア部材の各コア片の縁部の構成を示す断面図である。
【図６】実施の形態１を示す図で、巻線時のコア部材の姿勢を示す平面図である。
【図７】実施の形態１を示す図で、コア部材の他の連結手段を示す構成図である。
【図８】実施の形態１を示す図で、コア部材のさらに他の連結手段を示す構成図である。
【図９】実施の形態１を示す図で、永久磁石形電動機の縦断面図である。
【図１０】従来の鉄心装置における積層されたコア部材の各コア片の縁部の構成を示す断面図である。
【図１１】従来の鉄心装置における積層されたコア部材の各コア片の縁部で、図１０とは異なる構成を示す断面図である。
【符号の説明】
３コア片、３ａ凹部、３ｂ凸部、３ｃ，３ｄ端面、３ｅ透孔、３ｆ磁極ティース、３ｇかしめ結合用凸部、４第１コア部材、５第２コア部材、６巻線、７鉄心装置、１７ピン部材、２０，２１積層端部、２２積層中央部、２３薄肉部、２４固定子、２５回転子、２６永久磁石、２７回転子外周鉄部、２８磁束、５１第３コア部材。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electric motor used for a compressor or the like, and more particularly to a configuration of a stator core.
[0002]
[Prior art]
The applicant is disclosed in Japanese Patent Application Laid-Open No. 2000-201458 in which a first core member that continuously arranges a plurality of plate-like first core pieces and a second that continuously arranges a plurality of plate-like second core pieces. The core members are alternately displaced by a predetermined number in the stacking direction, the positions between the first core pieces of the first core member and the positions between the second core pieces of the second core member are shifted in the longitudinal direction, and each core piece The adjacent edges in the stacking direction are stacked so that the adjacent edges overlap each other, and connecting means for connecting the edges of the adjacent core pieces are provided. It has been proposed to produce an electric motor core formed in an annular or rectangular shape by rotating a piece.
[0003]
FIG. 10 is a cross-sectional view when the first core member and the second core member are alternately stacked one by one. In the figure, 4 is a first core member, 5 is a second core member, and 51 is a third core member which is the uppermost layer of the laminated core. By being configured in this way, the edges adjacent to each other in the stacking direction of the core pieces are stacked so that the end faces of the punched core pieces are alternately shifted by the overlapped dimension. (That is, since the end faces of the core pieces are not continuous), the area of the portion existing in the same plane is reduced, so that the generation of eddy currents can be suppressed, the iron loss can be reduced, and the magnetic performance can be improved. .
[0004]
FIG. 11 is a cross-sectional view when the first core member and the second core member are alternately laminated every two sheets. When a plurality of sheets are alternately overlapped, when each core piece is rotated by a connecting means (for example, a convex part and a concave part), the friction decreases and the productivity increases as the number of the plurality of sheets increases.
[0005]
[Problems to be solved by the invention]
The conventional electric motor is configured as described above, and in the case where the overlapping of the first core member 4 and the second core member 5 is alternated one by one, each core piece is connected to a connecting means (for example, a convex When the first core member 4 and the second core member 5 have a large friction when they are rotated by a part and a recess), especially when the lamination thickness is large or when the number of laminations is large due to the thin core member. There is a problem that a large force is required for rotation, and productivity deteriorates.
[0006]
Further, when the first core member 4 and the second core member 5 are alternately overlapped with each other, the problem of friction is reduced, but there is a problem that fine adjustment of the laminated thickness is difficult. . In general, the thickness of the motor core is controlled by taking the thickness of the core material in the core press as the command value. However, when the thickness of the core material varies within a lot, the core thickness varies. If this variation exceeds the control allowance, the core member corresponding to the end of the stack may be peeled off to finely adjust the stack thickness. Although the stacking thickness can be adjusted by peeling, a plurality of sheets are alternately overlapped. When the core member is peeled off, a plurality of sheets are peeled off together, and there is a problem that fine adjustment is difficult.
[0007]
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide an electric motor capable of reducing the core turning power during manufacture and finely adjusting the thickness.
[0008]
[Means for Solving the Problems]
  The iron core device according to the present invention includes a first core member that continuously arranges a plurality of plate-like first core pieces, and a second core member that continuously arranges a plurality of plate-like second core pieces. The positions between the first core pieces of the first core member and the positions between the second core pieces of the second core member are displaced in the longitudinal direction alternately in the stacking direction, and are adjacent to each other in the stacking direction of the core pieces. Are connected so that the edges of the core pieces adjacent to each other are connected to each other, and connecting means for connecting the edges of the adjacent core pieces are provided. In iron core equipment,One or more sheets are stacked alternatelyThe overlapping of the first core member and the second core member in the stacking direction is made smaller at the stack end than at the stack center.
[0009]
Further, in the iron core device according to the present invention, the overlapping of the first core member and the second core member in the stacking direction is made such that the stacking central portion is every plural pieces, and the stacking end portions are overlapped alternately one by one. It is characterized by.
[0011]
In the iron core device according to the present invention, the stacking direction of the first core member and the second core member is overlapped in the stacking end portion opposite to the stacking end portion where the through holes are provided, rather than the stacking central portion. It is characterized by a small number of sheets.
[0012]
In the iron core device according to the present invention, the first core member and the second core member are overlapped in the stacking direction, the stacking center portion is provided for each of a plurality of sheets, and the stacking layer is opposite to the stacking end portion where the through holes are provided. The end portions are alternately overlapped one by one.
[0014]
Moreover, as for the iron core apparatus which concerns on this invention, a connection means is on the one end side edge part front and back of the 1st core piece of a 1st core member, and the other end side edge part front and back of a 2nd core piece of a 2nd core member. It is formed by the recessed part and convex part which are respectively formed and the edge parts adjacent to the lamination direction of a core piece can fit.
[0015]
The iron core device according to the present invention is characterized in that the connecting means is a pin connection using a pin member.
[0016]
The iron core device according to the present invention is characterized in that the connecting means bends the thin portion of the back yoke.
[0017]
  A permanent magnet type electric motor according to the present invention comprises:7The iron core device according to any one of the above and a rotor provided with permanent magnets are provided.
[0018]
  The hermetic compressor according to the present invention is as follows.8The permanent magnet type motor described in 1 is used.
[0019]
The manufacturing method of the iron core device according to the present invention includes a first core member that continuously arranges a plurality of plate-like first core pieces and a second core that continuously arranges a plurality of plate-like second core pieces. The members are alternately arranged in the stacking direction, and the overlapping in the stacking direction of each core member is made smaller than the center of the stack at the number of the end portions of the stack, and the positions between the first core pieces of the first core member and the first core member. The step of laminating the two core members so that the positions between the second core pieces are shifted in the longitudinal direction and the adjacent edges overlap in the stacking direction of the core pieces, and the edges of the adjacent core pieces It is characterized by comprising a step of providing a connecting means for connecting each other, and a step of forming each core piece in an annular or rectangular shape by rotating the core pieces by the connecting means.
[0020]
In the manufacturing method of the iron core device according to the present invention, the stacking direction of the first core member and the second core member is set to be a plurality of stacked central portions, and the stacked end portions are alternately stacked. It is characterized by that.
[0028]
In addition, the manufacturing method of the iron core device according to the present invention is characterized in that after the core member is wound in a reverse warped state, each core piece is rotated by a connecting means to form an annular or rectangular shape. And
[0029]
  Moreover, the manufacturing method of the iron core device according to the present invention includes the first step in which the convex portion and the concave portion of the edge portion of the core piece are formed, and the concave and convex portion for caulking coupling of the laminated core is formed in the central portion of the core piece. As the second step of processing the first core member in the peripheral portion where the uneven portion is formed in the first step, the second step of forming both end surfaces and the peripheral portions of both end surfaces, and the first step As a second step of processing the second core member in the peripheral portion where the irregularities are formed, a third step of forming both end surfaces and peripheral portions of both end surfaces, and both ends in the second step and the third step The first core member and the second core member are respectively formed by sequentially pressing and punching the portion where the surface is formed, and the first core member and the second core member are sequentially laminated in the mold. And a plurality of first core members and a plurality of second core members, respectively. Alternately stacked one byIn each stacking direction, the overlapping in each stacking direction is less than the center of the stack and every few sheets at the stack end.When performing the press punching intermittent operation of the second step and the third step, respectivelyFor each overlapping numberIt is characterized by alternately performing a plurality of times.
  In addition, the manufacturing method of the iron core device according to the present invention includes a step of measuring the laminated thickness of the cores and, when thicker than the specified dimension value, removing one or more cores and adjusting the laminated thickness. It is characterized by that.
[0030]
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1 FIG.
Hereinafter, an example of an embodiment of the present invention will be described with reference to the drawings.
1 to 9 are views showing the first embodiment, FIG. 1 is a plan view showing the configuration of the iron core device, FIG. 2 is a plan view showing a process of forming the core member shown in FIG. 1 by press punching, and FIG. FIG. 4 is a cross-sectional view showing the structure of the connecting means for the core member formed through the process shown in FIG. 2, FIG. 4 is a plan view showing a state in which the core members formed through the process shown in FIG. 4 is a cross-sectional view showing the configuration of the edge of each core piece of the core members laminated as shown in FIG. 4, FIG. 6 is a plan view showing the posture of the core member during winding, and FIG. 7 is another connection of the core members FIG. 8 is a block diagram showing still another connecting means for the core member, and FIG. 9 is a longitudinal sectional view of the permanent magnet motor.
[0031]
In the figure, reference numeral 3 denotes a plate-like core piece made of a magnetic material, and convex portions 3b and concave portions 3a as connecting means are formed on the front and back surfaces of one end side edge portion, and the end surface 3c has the convex portions 3b and concave portions 3a. A concave arc-shaped end surface 3d that can be fitted to the end surfaces 3c of adjacent core pieces 3 is formed on the other end side.
[0032]
As shown in FIG. 2, reference numeral 4 denotes a first core member in which a plurality of core pieces 3 are continuously arranged via the end faces 3 c and 3 d. Reference numeral 5 denotes a second core member in which a plurality of core pieces 3 are continuously arranged via the end faces 3c and 3d. The core piece 3 of the first core member 4 has convex portions 3b and concave portions 3a as connecting means (that is, a connecting mechanism) formed on the front and back surfaces of one end side edge portion, and the core piece 3 of the second core member 5 is the other end. Convex portions 3b and concave portions 3a as connecting means (that is, a connecting mechanism) are formed on the front and back sides of the side edges.
[0033]
As shown in FIGS. 3-5, the 1st core member 4 and the 2nd core member 5 are laminated | stacked alternately, and each core piece position (namely, position between each core piece end surface 3c, 3d) of the 1st core member 4; The second core member 5 is laminated so that the positions between the core pieces (that is, the positions between the end faces 3c and 3d of the core pieces) are shifted in the longitudinal direction and the adjacent edges in the stacking direction of the core pieces overlap each other. ing. Then, at the edges of the core pieces 3 adjacent to each other in the stacking direction, the convex portions 3 b and the concave portions 3 a at the one end side edge of the core piece 3 of the first core member 4, and the core pieces 3 of the second core member 5 The projecting portion 3b and the recessed portion 3a at the end side edge are connected to each other so as to be freely rotatable.
[0034]
At this time, as shown in FIG. 5, the first core member 4 and the second core member 5 are alternately stacked at the central portion 22 in the stacking direction every plural sheets, and at the stacking end portions 20 and 21, the first core member 4 and the second core member 5 are alternately stacked one by one. Are stacked. In FIG. 5, two sheets are alternately stacked in the stacked central portion 22, but a plurality of sheets (for example, 2 to 10 sheets) may be alternately stacked as long as the characteristics described later allow. When the plurality of sheets are alternately overlapped, when the core pieces 3 are rotated by the connecting means (for example, the convex portion 3b and the concave portion 3a), the friction increases as the number of the plural pieces increases, and the productivity is improved. To do.
[0035]
However, on the other hand, as the number increases, the end faces 3c and 3d punched by the press exist in the same plane, and since there is no insulating film on the end faces, eddy currents are more likely to occur in the stacking direction. This eddy current has a problem of causing iron loss and lowering the magnetic performance.
[0036]
Further, the fitting between the convex portion 3b and the concave portion 3a at the one end side edge of the core piece 3 of the first core member 4 and the convex portion 3b and the concave portion 3a at the other end side edge of the core piece 3 of the second core member 5 is fitted. There arises a problem that the mechanical strength which has been given is lowered.
[0037]
That is, the number of laminated sheets is a value determined in consideration of productivity by reducing frictional force, magnetic performance, and mechanical strength. In addition, in the stacked end portions 20 and 21, the first core member 4 and the second core member 5 are overlapped with each other with respect to the stacked central portion 22 (one in the drawing). At this time, the length of the laminated end portions 20 and 21 is sufficiently shorter than the length of the laminated central portion 22, and the productivity, magnetic performance, and mechanical strength due to frictional force at the time of rotation are approximately the middle of the laminated portion. The characteristics of the portion 22 are obtained.
[0038]
In general, the thickness of the motor core is controlled by taking the thickness of the core material in the core press as the command value. However, when the thickness of the core material varies within a lot, the core thickness varies. If this variation exceeds the control tolerance, the core member corresponding to the stacking end portions 20 and 21 may be peeled off to finely adjust the stacking thickness. Although each core member can be peeled off and the stacking thickness can be adjusted, in the case of alternately overlapping each other, there is a problem that fine adjustment is difficult because a plurality of core members are peeled off when the core members are peeled off.
[0039]
However, according to the present invention, the stacked end portions 20 and 21 whose thicknesses are adjusted by peeling off the core member are superposed one by one or every necessary minimum, so that the product is improved for improving productivity. Even if the thickness center portion 22 is a plurality of wraps, the core thickness can be finely adjusted. Moreover, the lamination | stacking edge part may be an iron core upper part, lower part both sides, and may be one side.
[0040]
Normally, the laminated end 20 is provided with a through-hole 3e as shown in FIG. 3, and is fitted with a convex portion 3b at the edge of the core piece 3 and a caulking coupling convex portion 3g disposed at the center of the core piece 3. Combined. The through-holes 3e are provided so as to adjust the thickness of the core stack to a desired thickness in a press die that is continuously stacked, and so that the convex portions do not protrude from the core. For this reason, fine adjustment of the core thickness is adjusted by peeling off the laminated end 21 on the side opposite to the through hole 3e. In other words, in this sense, the stacking of the stacked end portions for each sheet or the necessary minimum number is required only at least on the stacked end portion 21 on the side opposite to the through holes 3e.
[0041]
Further, 6 in FIG. 1 is a winding wound around the magnetic pole teeth 3f (FIG. 4) of each core piece 3, and 7 is a concave and convex portion 3a of each core piece 3 of the laminated core members 4 and 5. 3b is an iron core device formed in an annular shape by rotating 3b. In addition, in FIG. 1, in the edge parts of the lamination | stacking core which laminated | stacked the 1st core member 4 and the 2nd core member 5 (joint of an annular body), in order to contact-connect edge parts, connection means (Convex part 3b and concave part 3a) are omitted.
[0042]
Next, a method for manufacturing the iron core device according to the first embodiment configured as described above will be described. First, at a position indicated by an arrow T in FIG. 2, convex portions and concave portions that can be press-fitted and fitted to the front and back surfaces of the core member are formed by press punching operation at three locations for each core piece. In this first stage, as shown in FIG. 3, convex portions 3 b and concave portions 3 a at the edge of the core piece 3 are formed, and a caulking coupling uneven portion of the laminated core is formed at the central portion of the core piece 3 ( 2 in the figure).
[0043]
At the position indicated by arrow A, both end faces 3c are formed by press-punching the portions indicated by hatching in the drawing as a second step in which the first core member 4 is processed in the peripheral portion where the irregularities are formed at the step indicated by arrow T. 3d and peripheral portions of both end faces 3c, 3d are formed. In addition, at the position indicated by the arrow B, as a second stage in which the second core member 5 is processed in the peripheral part where the irregularities were formed at the stage of the arrow T, the part indicated by hatching in the drawing is press-punched. The peripheral portions of both end faces 3c and 3d and both end faces 3c and 3d are formed.
[0044]
Next, at a position indicated by an arrow C in FIG. 2, a portion where both end faces 3c, 3d are formed at the stage of the arrow A and a part where both end faces 3c, 3d are formed at the stage of the arrow B are alternately illustrated. The first core member 4 and the second core member 5 are formed by press punching the portion indicated by the middle hatching, and the first core member 4 and the second core member 5 are sequentially laminated in the mold. .
[0045]
The press punching of the arrow A portion and the arrow B portion can perform an intermittent operation, and the first core member 4 press punched at the position of the arrow A is fed forward in the mold, and the arrow B At the position, it is fed forward without punching, and at the position indicated by the arrow C, the portion indicated by hatching in the drawing is press punched. In the case where the first core member 4 and the second core member 5 are alternately laminated, the second core member 5 that has been forward-punched without being punched at the position of the arrow A and press-punched at the position of the arrow B is then used. At the same time as the portion indicated by hatching in the figure is punched out at the position indicated by the arrow C, it is crimped and laminated on the first core member 4 punched out first. By repeating this sequentially, the first core member 4 and the second core member 5 are alternately laminated.
[0046]
When the first core member 4 and the second core member 5 are alternately stacked two by two, the intermittent operation of press punching of the arrow A part and the arrow B part is alternately performed every two times. After punching in the direction of the arrow-B without punching-the punching at the part of the arrow C, the "feeding in the direction of the arrow A without punching-the punching at the part of the arrow B-punching at the part of the arrow C" 2 Repeat continuously. By repeating this, the first core member 4 and the second core member 5 are alternately overlapped every two sheets. As described above, the plurality of sheets can be freely overlapped by the intermittent operation of press punching. If the intermittent operation is changed between the iron core laminated end and the laminated central part, the number of overlapping sheets can also be changed.
[0047]
Further, at the position indicated by the arrow S, three through holes are formed in each core piece at the same position as the concavo-convex portion formed at the stage of the arrow T by a press punching operation. Thereby, the three through-holes 3e which can fit the convex part 3b are formed in the core piece 3 used as the uppermost layer of a lamination | stacking core. At the position shown by the arrow B, as the second stage of processing the third core member 51 in the part where the through hole 3e was formed at the stage of the arrow S, the both end faces 3c are formed by press punching the part shown by hatching in the figure. 3d and peripheral portions of both end faces 3c, 3d are formed. At the position indicated by the arrow C, the third core member 51 is formed by press-punching the hatched portion in the drawing at the portion where the end faces 3c and 3d are formed at the stage of the arrow B, and the uppermost layer of the laminated core. Are stacked in a mold.
[0048]
For example, when it is desired to make the laminated thickness 75 mm, when the thickness of the core material is 0.35 mm, the number of laminated core pieces is about 214, and if the core piece with the through hole 3e is the 214th piece, Thus, a desired stacking layer thickness can be obtained.
[0049]
In FIG. 2, the core pieces 3 at both ends of the first core member 4 and the second core member 5 are partially uneven at the edge with the central core piece 3. This is because the core pieces 3 at both ends correspond to the end portions of the laminated core in which the first core member 4 and the second core member 5 are stacked, and the end portions are easily brought into contact with each other. Hereinafter, this is the reason why the core pieces at both ends of the laminated core are partially uneven with the central core piece.
[0050]
The recesses 3a and projections 3b, the through-holes 3e and the projections 3b facing each other in the stacking direction of the core pieces 3 in the mold are press-fitted and integrated with each other as shown in FIG. Is done. Then, the magnetic pole teeth 3f of the core pieces 3 of the laminated core members 4, 5 and 51 are wound in a state where the core member is linearly expanded as shown in FIG. 4 or in a state where the core member is reversely warped as shown in FIG. After the wire 6 (not shown) is applied, the recessed portion 3a and the protruding portion 3b, the through hole 3e and the protruding portion 3b that are fitted are rotated to form an annular shape, thereby completing the iron core device 7.
[0051]
FIG. 4 shows the case where the core pieces 3 are arranged in a straight line. However, if the winding is performed in the reverse warped state as shown in FIG. 6, the winding workability is further improved.
[0052]
In the above manufacturing method, the core member is punched in an example in which the core pieces are arranged in a straight line, but the core pieces may be punched out so as to be arranged in an annular shape of the final motor core. A motor with higher accuracy can be obtained by press punching in advance with the final shape as the motor core, then unfolding the core piece, winding it, and returning it to the punched annular shape.
[0053]
Moreover, in this Embodiment, although the example in the recessed part and convex part which can be fitted is shown as a connection means which connects edge parts, as a connection means, as shown in FIG. The pin connection used may be used, or the same effect can be obtained with the type in which the thin portion 23 of the back yoke is bent as shown in FIG. 8, but the core piece is provided with a concave portion and a convex portion. Forms are the most accurate and effective in production.
[0054]
Further, in the case of an electric motor using a permanent magnet as a rotor, such as a brushless DC motor, the following effects can be expected. FIG. 9 is a longitudinal sectional view of a permanent magnet type electric motor. In general, the permanent magnet type electric motor is thicker in the rotor 25 than in the stator 24. This is to effectively use the magnetic force of the permanent magnet 26, and the magnetic flux 28 indicated by the arrow of the permanent magnet of the rotor overhanging from the stator passes through the rotor outer peripheral iron portion 27 and goes around the stator. For this reason, the magnetic flux density of the stator is higher at the laminated end portions 20 and 21 than at the laminated central portion 22, and eddy currents at the end faces 3c and 3d between the core pieces are more likely to be generated. Since the number of overlaps at the end of the stack is small, the influence of eddy current can be reduced and an efficient permanent magnet motor can be obtained.
[0055]
Further, if the permanent magnet type motor is used in a hermetic compressor, the performance of the hermetic compressor can be improved.
[0056]
【The invention's effect】
In the iron core device according to claim 1 of the present invention, the overlapping in the stacking direction of each of the first core member and the second core member is performed at a smaller number at the stacking end portion than at the stacking central portion. At the same time, it is possible to reduce the force when the core piece is rotated in order to unfold the laminated iron core so that winding is easy, and fine adjustment of the laminated thickness of the iron core is facilitated.
[0057]
In the iron core device according to claim 2 of the present invention, the stacking direction of the first core member and the second core member is overlapped in a plurality of sheets in the stacking central portion, and the stacking end portions are alternately stacked in one stack. By doing so, it is possible to reduce the force when the core piece is rotated in order to expand the laminated core so as to be easily wound during winding, and to facilitate fine adjustment of the laminated thickness of the core.
[0059]
  Further, the claims of the present invention3In the iron core device according to the present invention, the stacking of the first core member and the second core member in the stacking direction is less than the center of the stack at each stack end opposite to the stack end where the through holes are provided. By doing so, fine adjustment of an iron core lamination layer thickness can be performed reliably.
[0060]
  Further, the claims of the present invention4In the iron core device according to the present invention, the stacking direction of the first core member and the second core member is overlapped with each other in the stacking central portion, and the stacking end on the side opposite to the stacking end provided with the through hole is one. By overlapping each sheet alternately, fine adjustment of the core stack thickness can be performed reliably.
[0062]
  Further, the claims of the present invention5In the iron core device according to the first aspect of the present invention, the connecting means is formed on one end side edge front and back surfaces of the first core piece of the first core member and on the other end side edge front and back surfaces of the second core piece of the second core member, respectively. By comprising the recessed part and convex part which can fit the edge parts which adjoin in the lamination direction of a core piece, a precision and high productivity iron core apparatus can be obtained.
[0063]
  Further, the claims of the present invention6In the iron core apparatus according to the present invention, since the connecting means is a pin connection using a pin member, an iron core apparatus with high accuracy and high productivity can be obtained.
[0064]
  Further, the claims of the present invention7In the iron core device according to the present invention, since the connecting means bends the thin portion of the back yoke, a highly productive iron core device can be obtained.
[0065]
  Claims of the invention8A permanent magnet type electric motor according to claim 1.7By providing the iron core device according to any one of the above and a rotor provided with a permanent magnet, a highly efficient permanent magnet motor can be obtained.
[0066]
  Claims of the invention9A hermetic compressor according to claim8A high-performance hermetic compressor can be obtained by using the permanent magnet type motor described in 1).
[0067]
  Claim 1 of the present invention0The manufacturing method of the iron core device according to the present invention includes: a first core member that continuously arranges a plurality of plate-like first core pieces; and a second core member that continuously arranges a plurality of plate-like second core pieces; The positions of the first core members between the first core members and the second cores are alternately arranged in the stacking direction and the stacking of the core members in the stacking direction is smaller than the central portion of the stack. The step of laminating such that the positions between the second core pieces of the member are shifted in the longitudinal direction and the adjacent edges overlap in the stacking direction of the core pieces, and the edges of the adjacent core pieces are In order to develop the laminated iron core so that it can be easily wound at the time of winding by providing a step of providing a connecting means to be connected and a step of forming each core piece into an annular or rectangular shape by rotating each core piece by the connecting means In addition to reducing the force when rotating the core piece, the fine adjustment of the core stack thickness It becomes easy.
[0068]
  Moreover, Claim 1 of this invention1In the manufacturing method of the iron core device according to the present invention, the stacking direction of the first core member and the second core member is set to be a plurality of stacked central portions and the stacked end portions are alternately stacked one by one. In addition, it is possible to reduce the force when the core piece is rotated in order to expand the laminated iron core so that it can be easily wound during winding, and the fine adjustment of the laminated thickness of the iron core is facilitated.
[0076]
  Further, the claims of the present invention12According to the manufacturing method of the iron core device according to the present invention, the winding workability is obtained by forming each core piece in an annular or rectangular shape by rotating each core piece with a connecting means after winding in a state where the core member is reversely warped. Is improved.
[0077]
  Further, the claims of the present invention13The manufacturing method of the iron core device according to the first step in which the convex part and the concave part of the edge of the core piece are formed, and the concave and convex part for caulking coupling of the laminated core is formed in the center part of the core piece, As a second step of processing the first core member in the peripheral portion where the uneven portion is formed in the process, the second step of forming both end surfaces and the peripheral portion of both end surfaces, and the uneven portion is formed in the first step. As a second step of processing the second core member in the peripheral portion, a third step of forming both end surfaces and peripheral portions of both end surfaces, and both end surfaces are formed in the second step and the third step. The first core member and the second core member are respectively formed by press punching the portions alternately and sequentially, and the first core member and the second core member are sequentially laminated in the mold. And alternately stacking a plurality of first core members and a plurality of second core members.In each stacking direction, the overlapping in each stacking direction is less than the center of the stack and every few sheets at the stack end.When performing the press punching intermittent operation of the second step and the third step, respectivelyFor each overlapping numberBy alternately performing a plurality of times, it is possible to freely overlap each other.
  Further, in the method for manufacturing an iron core device according to claim 14 of the present invention, the thickness of the core is measured, and if the thickness is larger than the specified dimension value, one or a plurality of cores are peeled off to adjust the thickness. By providing the step to perform, the iron core thickness can be finely adjusted.
[Brief description of the drawings]
FIG. 1 shows the first embodiment and is a plan view showing the configuration of an iron core device.
FIG. 2 is a plan view showing a step of forming the core member shown in FIG. 1 by press punching.
3 is a cross-sectional view showing a configuration of a connecting means for core members formed through the process shown in FIG. 2;
4 is a plan view showing a state in which core members formed through the steps shown in FIG. 2 are stacked. FIG.
FIG. 5 is a cross-sectional view showing a configuration of an edge portion of each core piece of core members stacked as shown in FIG. 4;
FIG. 6 shows the first embodiment and is a plan view showing the posture of the core member during winding.
FIG. 7 shows the first embodiment, and is a configuration diagram showing another connecting means of the core member.
FIG. 8 is a diagram showing the first embodiment and is a configuration diagram showing still another connecting means of the core member.
FIG. 9 is a view showing the first embodiment and is a longitudinal sectional view of a permanent magnet type electric motor.
FIG. 10 is a cross-sectional view illustrating a configuration of an edge portion of each core piece of a core member stacked in a conventional iron core device.
11 is a cross-sectional view showing a configuration different from that of FIG. 10 at the edge of each core piece of the laminated core member in the conventional iron core device.
[Explanation of symbols]
3 core pieces, 3a concave portions, 3b convex portions, 3c, 3d end faces, 3e through holes, 3f magnetic pole teeth, 3g caulking coupling convex portions, 4 first core member, 5 second core member, 6 windings, 7 iron core device , 17 Pin member, 20, 21 Stack end, 22 Stack center, 23 Thin section, 24 Stator, 25 Rotor, 26 Permanent magnet, 27 Rotor outer peripheral iron section, 28 Magnetic flux, 51 Third core member.

Claims

The first core member that continuously arranges a plurality of plate-like first core pieces and the second core member that continuously arranges a plurality of plate-like second core pieces, alternately in the stacking direction, The positions between the first core pieces of the first core member and the positions between the second core pieces of the second core member are shifted in the longitudinal direction, and adjacent edges in the stacking direction of the core pieces overlap each other. In the iron core device formed in a ring shape or a rectangular shape by connecting the edges of the core pieces adjacent to each other and provided with connecting means, and rotating the core pieces by the connecting means, The overlapping of the first core member and the second core member, which are alternately stacked one by one or a plurality of sheets, in the stacking direction is set to be smaller at the stack end than at the stack center. Iron core device to do.

The stacking direction of the first core member and the second core member is overlapped in a plurality of sheets at the center of the stack, and the stacking end portions are alternately overlapped one by one. The iron core device described.

The overlapping of the first core member and the second core member in the stacking direction is made smaller for each number of sheets at the stacking end portion opposite to the stacking end portion where the through holes are provided than the stacking center portion. The iron core device according to claim 1.

The stacking direction of the first core member and the second core member is overlapped with each other in the stacking center portion, and the stacking end portion opposite to the stacking end portion where the through holes are provided is alternately stacked one by one. The iron core device according to claim 3 , wherein the iron core device is overlapped.

The connection means is formed on one end side edge front and back surfaces of the first core piece of the first core member and on the other end side edge front and back surfaces of the second core piece of the second core member, respectively. core device according to any one of claims 1 to 4 Aitonaru edge portions in the stacking direction is characterized by being composed by fittable recesses and protrusions.

The iron core device according to any one of claims 1 to 4, wherein the connecting means is a pin connection using a pin member.

The iron core device according to any one of claims 1 to 4, wherein the connecting means is configured to bend a thin portion of a back yoke.

And the iron core according to any one of claims 1 to 7, the permanent magnet type motor characterized by comprising a rotor provided with permanent magnets.

A hermetic compressor using the permanent magnet motor according to claim 8 .

A first core member that continuously arranges a plurality of plate-like first core pieces and a second core member that continuously arranges a plurality of plate-like second core pieces, alternately in the stacking direction, and The overlapping positions of the core members in the stacking direction are smaller at the stack end than at the stack center, and the positions of the first core members between the first core members and the second core members of the second core member are smaller. A step of laminating the adjacent core pieces in the stacking direction of the core pieces and a connecting means for connecting the adjacent edge portions of the core pieces are provided. A method of manufacturing an iron core device, comprising: a step; and a step of forming each core piece in an annular or rectangular shape by rotating the core piece by the connecting means.

Overlapping alignment in the stacking direction of the first core member and the second core member, the laminated central portion is a plurality every claim 1 0 stack end is characterized in that the overlap for each one alternately The manufacturing method of the iron core apparatus as described in 2 ..

After being subjected to the winding core member opposite warped state, manufacture of the core according to claim 1 0, characterized by an annular shape or a rectangular shape by rotating the core pieces in the coupling means Method.

A first step in which a convex portion and a concave portion of the edge of the core piece are formed, and a concave and convex portion for caulking and coupling of the laminated core is formed in the central portion of the core piece;
A second step of forming both end surfaces and peripheral portions of both end surfaces as a second step of processing the first core member in the peripheral portion where the irregularities are formed in the first step;
As a second step of processing the second core member in the peripheral portion where the uneven portion is formed in the first step, a third step of forming both end surfaces and peripheral portions of both end surfaces;
The first core member and the second core member are formed by alternately pressing and punching the portions where both end faces are formed in the second step and the third step, respectively. A fourth step in which the two-core member is sequentially laminated in the mold;
Each of the first core member and the second core member are alternately stacked , and the stacking direction in each stacking direction is set to be smaller at the stacking end portion than at the stacking center portion . A method of manufacturing an iron core device, wherein the intermittent operation of press punching in the step 2 and the third step is alternately performed a plurality of times for each overlapping number of sheets .

14. The method according to claim 10, further comprising a step of measuring the thickness of the cores and adjusting the thickness of the cores by peeling one or more cores when the thickness is larger than a specified dimension value. A method for manufacturing the iron core device according to claim 1.