JP4028100B2

JP4028100B2 - Stator for rotating electrical machine and method for manufacturing stator

Info

Publication number: JP4028100B2
Application number: JP24508198A
Authority: JP
Inventors: 敏一佐藤; 豊信山田; 勉川村
Original assignee: Toshiba Corp
Current assignee: Toshiba Corp
Priority date: 1998-08-31
Filing date: 1998-08-31
Publication date: 2007-12-26
Anticipated expiration: 2018-08-31
Also published as: JP2000078779A

Description

【０００１】
【発明の属する技術分野】
本発明は、複数の分割コアからなる環状のステータコアを有する回転電機のステータに関する。
【０００２】
【発明が解決しようとする課題】
回転電機においては、複数の分割コアを環状に組合わせることからステータコアが形成された構成のものがある。この構成の場合、各分割コアの周方向端面（＝分割面）が平面状に形成されており、平面状の分割面が周方向に隣接する平面状の分割面に接合されている。このため、分割面相互間で磁束の損失が生じ、磁気効率が低下する虞れがある。
本発明は上記事情に鑑みてなされたものであり、その目的は、磁気効率の低下を抑えることができる回転電機のステータを提供することにある。
【０００３】
【課題を解決するための手段】
請求項１記載の回転電機のステータは、複数枚の第１の鋼板および複数枚の第２の鋼板を第１の鋼板および第２の鋼板が交互に並ぶように積層することに基づいて形成されたものであって円弧状をなす分割ヨークおよび分割ヨークから内周側へ突出する直状の磁極ティースを有する複数の分割コアと、前記複数枚の第１の鋼板のそれぞれに周方向の一端部に位置して形成されたものであって前記磁極ティースの延び方向に対して平行な直線状をなす第１の平行面と、前記複数枚の第２の鋼板のそれぞれに前記第１の平行面とは反対側である周方向の他端部に位置して形成されたものであって前記磁極ティースの延び方向に対して平行な直線状をなす第２の平行面と、前記複数枚の第１の鋼板のそれぞれに前記第１の平行面とは反対側である周方向の他端部に位置して形成されたものであって前記第２の平行面の外周側の始点を基準に前記第２の平行面に対して傾斜する直線状をなすと共に外周部から内周部に向うに従って前記磁極ティースに接近するように傾斜する第１の傾斜面と、前記複数枚の第２の鋼板のそれぞれに前記第２の平行面とは反対側である周方向の一端部に位置して形成されたものであって前記第１の平行面の外周側の始点を基準に前記第１の平行面に対して前記第１の傾斜面と同一角度で傾斜する直線状をなすと共に外周部から内周部に向うに従って前記磁極ティースに接近するように傾斜する第２の傾斜面と、前記複数の分割コアのそれぞれの周方向の一端部に形成されたものであって前記第１の平行面および前記第２の傾斜面を交互に有する櫛歯状をなすと共に軸方向視が三角形状をなす第１の櫛歯部と、前記複数の分割コアのそれぞれの周方向の他端部に形成されたものであって前記第１の傾斜面および前記第２の平行面を交互に有する櫛歯状をなすと共に軸方向視が三角形状をなす第２の櫛歯部と、前記複数の分割コアを相互に連結してなるものであって前記複数の第１の櫛歯部のそれぞれを周方向に隣接する前記第２の櫛歯部に前記第１の櫛歯部および前記第２の櫛歯部相互間が軸方向にラップし且つ前記第１の平行面および前記第２の傾斜面相互間が接触し且つ前記第１の傾斜面および前記第２の平行面相互間が接触するように噛合させてなる円環状のステータコアを備えたところに特徴を有している。
上記手段によれば、分割コアの櫛歯部が周方向に隣接する櫛歯部に軸方向から噛合し、周方向にラップしている。このため、分割コアから周方向に隣接する分割コアに流れる磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、周方向に隣接する櫛歯部相互間の周方向のラップ量が増える。このため、分割コアから隣接する分割コアに流れる磁束の損失量が一層少なくなり、磁気的な効率が一層向上する。
【０００５】
請求項２記載の回転電機のステータは、分割コアに軸方向へ延びる切欠部が形成されているところに特徴を有している。
上記手段によれば、例えば複数の分割コアを環状に接合する際に切欠部の内面を治具に押し当て、複数の分割コアを環状に位置決めできる。
【０００６】
請求項３記載の回転電機のステータは、分割コアに軸方向へ延びる溶接用の切欠部が形成されているところに特徴を有している。
上記手段によれば、溶接代が大きくなり、磁性板間の溶接強度が強くなるので、ステータコアの機械的な強度が高まる。
【０００７】
請求項４記載の回転電機のステータは、複数枚の第１の鋼板および複数枚の第２の鋼板を第１の鋼板および第２の鋼板が交互に並ぶように積層することに基づいて形成されたものであって円弧状をなす分割ヨークおよび分割ヨークから内周側へ突出する直状の磁極ティースを有する複数の分割コアと、前記複数枚の第１の鋼板のそれぞれに周方向の一端部に位置して形成されたものであって前記磁極ティース側へ凹む逆「く」字状をなす第１の屈曲面と、前記複数枚の第２の鋼板のそれぞれに前記第１の屈曲面とは反対側である周方向の他端部に位置して形成されたものであって前記磁極ティース側へ凹む逆「く」字状をなす第２の屈曲面と、前記複数枚の第１の鋼板のそれぞれに前記第１の屈曲面とは反対側である周方向の他端部に位置して形成されたものであって前記磁極ティースとは反対側へ出張る「く」字状をなす第３の屈曲面と、前記複数枚の第２の鋼板のそれぞれに前記第２の屈曲面とは反対側である周方向の一端部に位置して形成されたものであって前記磁極ティースとは反対側へ出張る「く」字状をなす第４の屈曲面と、前記複数の分割コアのそれぞれの周方向の一端部に形成されたものであって前記第１の屈曲面および前記第３の屈曲面を交互に有する櫛歯状をなす第１の櫛歯部と、前記複数の分割コアのそれぞれの周方向の他端部に形成されたものであって前記第２の屈曲面および前記第４の屈曲面を交互に有する櫛歯状をなす第２の櫛歯部と、前記複数の分割コアを相互に連結してなるものであって前記複数の第１の櫛歯部のそれぞれを周方向に隣接する前記第２の櫛歯部に前記第１の櫛歯部および前記第２の櫛歯部相互間が軸方向にラップし且つ前記第１の屈曲面および前記第３の屈曲面相互間が接触し且つ前記第２の屈曲面および前記第４の屈曲面相互間が接触するように噛合させてなる円環状のステータコアを備えたところに特徴を有している。
上記手段によれば、磁束が櫛歯部の周方向端面に同時に突入することがなくなるので、磁束の損失量が一層少なくなり、磁気的な効率が一層高まる。
【０００８】
請求項５記載のステータの製造方法は、請求項１記載のステータを製造する場合に、磁性板を裏返して磁性板に重ねることに基づいて両端部に第１の櫛歯部および第２の櫛歯部を有する分割コアを形成するところに特徴を有している。
上記手段によれば、輪郭形状が異なる２種類の磁性板を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
【０００９】
請求項６記載のステータの製造方法は、請求項１記載のステータを製造する場合に、磁性板の向きを反転して磁性板に重ねることに基づいて両端部に第１の櫛歯部および第２の櫛歯部を有する分割コアを形成するところに特徴を有している。
上記手段によれば、輪郭形状が異なる２種類の磁性板を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
【００１０】
【発明の実施の形態】
以下、本発明の第１実施例を図１ないし図５に基づいて説明する。尚、本実施例は、本発明をインナーロータ形の３相ＤＣブラシレスモータに適用したものである。まず、図１の（ａ）において、各分割コア１は円弧状の分割ヨーク２と直状の磁極ティース３と磁極片４とを有するものであり、図１の（ｂ）に示すように、磁性板に相当する第１の鋼板５および第２の鋼板６を軸方向へ１枚おきに交互に積層して機械的に連結する（例えばかしめ付け，溶接等）ことから形成されている。
【００１１】
第１の鋼板５は、図５に示すように、帯状鋼板７から一列に打抜かれたものであり、第１の鋼板５の周方向一端部には、図４に示すように、磁極ティース３に平行な直線状の平行面８が形成され、第１の鋼板５の周方向他端部には、中心線ＣＬに対して一方向へθ°傾斜する直線状の傾斜面９が形成されている。尚、中心線ＣＬは磁極ティース３に平行な直線を称するものである。
【００１２】
第２の鋼板６は、帯状鋼板７から第１の鋼板５を一列に打抜いた後に所定の鋼板５を裏返すことに基づいて形成されたものであり、第２の鋼板６の周方向一端部には、図４に示すように、中心線ＣＬに対して傾斜面９とは反対方向へθ°傾斜する直線状の傾斜面１０が形成され、第２の鋼板６の周方向他端部には、磁極ティース３に平行な直線状の平行面８が形成されている。
【００１３】
各分割コア１には、図１の（ａ）に示すように、分割ヨーク２の周方向両端部に位置してラップ部１１が形成されている。これら各ラップ部１１は軸方向視が三角形状をなすものであり、各分割コア１の周方向一端部に位置するラップ部１１は、第１の鋼板５の平行面８と第２の鋼板６の傾斜面１０とからなる櫛歯状をなし、各分割コア１の周方向他端部に位置するラップ部１１は、第１の鋼板５の傾斜面９と第２の鋼板６の平行面８とからなる櫛歯状をなしている。尚、ラップ部１１は櫛歯部に相当するものである。
【００１４】
図２のステータコア１２は６個の分割コア１を円環状に組合わせてなるものであり、各ラップ部１１は周方向に隣接するラップ部１１に軸方向から噛合し、周方向に隣接するラップ部１１に周方向にラップしている。これら軸方向に噛合する各組のラップ部１１間には軸方向に沿ってレーザー溶接が施されており、６個の分割コア１はレーザー溶接によって円環状に保持されている。
【００１５】
ステータコア１２には、図３の（ａ）に示すように、各磁極ティース３に対応して合成樹脂製のモールド層１３が形成されている。これら各モールド層１３は、図３の（ｂ）に示すように、磁極ティース３の表面を覆う角筒状のコイル巻装部１４と、コイル巻装部１４の内周部に位置する鍔部１５と、分割ヨーク２の軸方向上端面を覆う円弧状の端板部１６と、分割ヨーク２の軸方向下端面を覆う円弧状の端板部１７とから構成されたものであり、ステータコア１２を成形型（図示せず）内に収納して溶融樹脂を注入するインサート成形に基づいて形成されている。
【００１６】
各磁極ティース３には、コイル巻装部１４の上からコイル１８が装着されている。これら各コイル１８は、分割コア１を円環状に組合わせる前に磁極ティース３に巻装されたものであり、図３の（ａ）に示すように、巻回方向を外周側から内周側および内周側から外周側へ層毎に反転させながら略階段状に巻回されている。
【００１７】
上記実施例によれば、分割コア１の周方向両端部にラップ部１１を形成し、各ラップ部１１を周方向に隣接するラップ部１１に軸方向から噛合させ、周方向にラップさせた。このため、分割コア１から周方向に隣接する分割コア１に流れる磁束の損失量が少なくなるので、磁気的な効率が向上する。
【００１８】
また、分割コア１の一方のラップ部１１の端面を第１の鋼板５の平行面８および第２の鋼板６の傾斜面１０から構成し、他方のラップ部１１の端面を第１の鋼板５の傾斜面９および第２の鋼板６の平行面８から構成した。このため、ラップ部１１相互間の周方向のラップ量が増えるので、分割コア１から周方向に隣接する分割コア１に流れる磁束の損失量が一層少なくなり、磁気的な効率が一層向上する。
【００１９】
また、第１の鋼板５を裏返して第１の鋼板５に重ねることに基づいて分割コア１を形成した。このため、第１の鋼板５および第２の鋼板６を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
【００２０】
次に本発明の第２実施例を図６に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。各分割コア１には、分割ヨーク２および磁極片４に位置して軸方向へ延びる切欠部１９および２０が形成されており、前者の各切欠部１９は外周側が開口する半円形状をなし、後者の各切欠部２０は内周側が開口する半円形状をなしている。
【００２１】
各切欠部１９および２０は、切欠部を有する第１の鋼板５および第２の鋼板６を積層することに基づいて形成されたものであり、各分割コア１は、切欠部１９および２０の内面に沿ってレーザー溶接を施すことに基づいて機械的に連結されている。
【００２２】
上記実施例によれば、分割コア１に切欠部１９および２０を形成した。このため、例えば複数の分割コア１を円環状に溶接する際に切欠部１９の内面および切欠部２０の内面を治具に押し当て、複数の分割コア１を円環状に位置決めできるので、ステータコア１２の真円度が高まる。
また、切欠部１９および２０に沿ってレーザー溶接を施すことに基づいて第１の鋼板５および第２の鋼板６を接合したので、溶接部の突出が防止される。これと共に、溶接代が大きくなり、第１の鋼板５および第２の鋼板６間の溶接強度が強くなるので、ステータコア１２の機械的な強度が高まる。
【００２３】
尚、上記第２実施例においては、分割コア１に２種類の切欠部１９および２０を形成したが、これに限定されるものではなく、例えば切欠部１９および２０のいずれか一方を形成しても良い。
また、上記第２実施例においては、切欠部１９および２０に沿ってレーザー溶接を施したが、これに限定されるものではなく、例えばアーク溶接を施しても良い。
【００２４】
次に本発明の第３実施例を図７に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第１の鋼板５の周方向一端部には、図７の（ｂ）に示すように、逆「く」字状の屈曲面２１が形成され、第１の鋼板５の周方向他端部には、「く」字状の屈曲面２２が形成されている。また、第２の鋼板６は、第１の鋼板５を裏返すことに基づいて形成されたものであり、第２の鋼板６の周方向一端部には屈曲面２２が形成され、第２の鋼板６の周方向他端部には屈曲面２１が形成されている。
【００２５】
各分割コア１には、図７の（ａ）に示すように、分割ヨーク２の周方向両端部に位置して櫛歯部に相当するラップ部２３が形成されている。これら各ラップ部２３は屈曲面２１および２２を交互に有する櫛歯状をなすものであり、周方向に隣接するラップ部２３に軸方向から噛合し、周方向にラップしている。
【００２６】
上記実施例によれば、ラップ部２３の周方向端面を第１の屈曲面２１および第２の屈曲面２２から構成した。このため、磁束がラップ部２３の周方向端面に同時に突入することがなくなるので、磁束の損失量が一層少なくなり、磁気的な効率が一層高まる。
【００２７】
尚、上記第３実施例においては、屈曲面２１および２２を滑らかな屈曲面状に形成したが、これに限定されるものではなく、本発明の第４実施例を示す図８のように、直線的な屈曲面状に形成しても良い。
【００２８】
また、上記第１〜第４実施例においては、帯状鋼板７から第１の鋼板５を１列に打抜いたが、これに限定されるものではなく、例えば本発明の第５実施例を示す図９のように、磁極ティース３が対向する状態で偶数列（例えば２列）に打抜き、上列の第１の鋼板５の向きを１８０°変更して第２の積層板６と同一の輪郭形状にした後、下列の第１の鋼板５に重ね、分割コア１を形成すると良い。この構成の場合でも、第１の鋼板５および第２の鋼板６を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
【００２９】
また、上記第１〜第５実施例においては、第１の鋼板５および第２の鋼板６を１枚ずつ交互に積層したが、これに限定されるものではなく、複数枚（例えば２枚）ずつ交互に積層しても良い。
【００３０】
【発明の効果】
以上の説明から明らかなように、本発明の回転電機のステータは次の効果を奏する。
請求項１記載の手段によれば、分割コアの櫛歯部を周方向に隣接する櫛歯部に軸方向から噛合させ、周方向にラップさせた。このため、分割コアから周方向に隣接する分割コアに流れる磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、櫛歯部の周方向端面を平行面と傾斜面とから構成した。このため、櫛歯部相互間の周方向のラップ量が増えるので、分割コアから周方向に隣接する分割コアに流れる磁束の損失量が一層少なくなり、磁気的な効率が一層向上する。
【００３１】
請求項２記載の手段によれば、分割コアに切欠部を形成した。このため、例えば複数の分割コアを環状に接合する際に切欠部の内面を治具に押し当て、複数の分割コアを環状に位置決めできる。
【００３２】
請求項３記載の手段によれば、分割コアの切欠部に沿って溶接を施したので、溶接部の突出が防止される。これと共に、溶接代が大きくなり、磁性板間の溶接強度が強くなるので、ステータコアの機械的な強度が高まる。
請求項４記載の手段によれば、櫛歯部の周方向端面を複数種の屈曲面から構成した。このため、磁束が櫛歯部の周方向端面に同時に突入することがなくなるので、磁束の損失量が一層少なくなり、磁気的な効率が一層高まる。
【００３３】
請求項５記載の手段によれば、磁性板を裏返して磁性板に重ねることに基づいて分割コアを形成した。このため、輪郭形状が異なる２種類の磁性板を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
請求項６記載の手段によれば、磁性板の向きを反転して磁性板に重ねることに基づいて分割コアを形成した。このため、輪郭形状が異なる２種類の磁性板を別個のプレス機を用いて打抜く必要がなくなるので、プレス装置が簡単で小形なものになる。
【図面の簡単な説明】
【図１】本発明の第１実施例を示す図（ａは分割コアを示す平面図、ｂはＸ−Ｘ線に沿う断面図）
【図２】ステータコアを示す平面図
【図３】（ａ）はステータコアをコイルの巻装状態で示す平面図、（ｂ）はＸ−Ｘ線に沿う断面図
【図４】第１の鋼板および第２の鋼板を示す平面図
【図５】第１の鋼板の打抜き状態を示す図
【図６】本発明の第２実施例を示す図（分割コアを示す平面図）
【図７】本発明の第３実施例を示す図（ａは分割コアを示す平面図、ｂは第１の鋼板および第２の鋼板を示す平面図）
【図８】本発明の第４実施例を示す図（ａは分割コアを示す平面図、ｂは第１の鋼板および第２の鋼板を示す平面図）
【図９】本発明の第５実施例を示す図（第１の鋼板の打抜き状態を示す平面図）
【符号の説明】
１は分割コア、３は磁極ティース、５は第１の鋼板（磁性板）、６は第２の鋼板（磁性板）、８は平行面、９および１０は傾斜面、１１はラップ部（櫛歯部）、１２はステータコア、１９および２０は切欠部、２１および２２は屈曲面、２３はラップ部（櫛歯部）を示す。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a stator for a rotating electrical machine having an annular stator core composed of a plurality of divided cores.
[0002]
[Problems to be solved by the invention]
Some rotary electric machines have a configuration in which a stator core is formed by combining a plurality of divided cores in an annular shape. In the case of this configuration, the circumferential end face (= divided surface) of each divided core is formed in a planar shape, and the planar divided surface is joined to a planar divided surface adjacent in the circumferential direction. For this reason, a loss of magnetic flux occurs between the divided surfaces, and the magnetic efficiency may be reduced.
This invention is made | formed in view of the said situation, The objective is to provide the stator of the rotary electric machine which can suppress the fall of magnetic efficiency.
[0003]
[Means for Solving the Problems]
The stator of the rotating electrical machine according to claim 1 is formed based on laminating a plurality of first steel plates and a plurality of second steel plates so that the first steel plates and the second steel plates are alternately arranged. A plurality of split cores each having an arc-shaped split yoke and a straight magnetic pole tooth projecting inward from the split yoke, and one end portion in the circumferential direction of each of the plurality of first steel plates A first parallel surface formed in a straight line parallel to the extending direction of the magnetic pole teeth, and the first parallel surface on each of the plurality of second steel plates. A second parallel surface that is formed at the other end portion in the circumferential direction opposite to the first side and that is formed in a straight line parallel to the extending direction of the magnetic pole teeth, and Each of the steel plates has a circumference that is opposite to the first parallel surface. The second parallel surface is formed on the other end portion of the second parallel surface, and forms a straight line inclined with respect to the second parallel surface with respect to the start point on the outer peripheral side of the second parallel surface, and from the outer peripheral portion. A first inclined surface that inclines so as to approach the magnetic pole teeth toward the peripheral portion, and one end portion in the circumferential direction that is opposite to the second parallel surface on each of the plurality of second steel plates And is formed in a straight line that is inclined at the same angle as the first inclined surface with respect to the first parallel surface with respect to a starting point on the outer peripheral side of the first parallel surface. And a second inclined surface that is inclined so as to approach the magnetic pole teeth from the outer peripheral portion toward the inner peripheral portion, and one end portion in the circumferential direction of each of the plurality of divided cores. When a comb-like shape having alternately one parallel surface and the second inclined surface is formed Are formed at the first comb-tooth portion having a triangular shape when viewed in the axial direction, and at the other circumferential end of each of the plurality of divided cores, the first inclined surface and the second A plurality of first combs are formed by connecting a plurality of divided cores with a second comb tooth having a comb shape having alternating parallel surfaces and a triangular shape when viewed in the axial direction. The first comb teeth and the second comb teeth overlap each other in the axial direction with the second comb teeth adjacent to each other in the circumferential direction, and the first parallel surface and It has a feature in that an annular stator core is formed so that the second inclined surfaces are in contact with each other and the first inclined surface and the second parallel surfaces are in contact with each other. Yes.
According to the said means, the comb-tooth part of the split core meshes with the comb-tooth part adjacent to the circumferential direction from the axial direction, and is wrapped in the circumferential direction. For this reason, since the loss amount of the magnetic flux which flows into the division core adjacent to the circumferential direction from a division core decreases, magnetic efficiency improves. Moreover, the circumferential wrap amount between the comb teeth adjacent in the circumferential direction increases. For this reason, the loss amount of the magnetic flux flowing from the split core to the adjacent split core is further reduced, and the magnetic efficiency is further improved.
[0005]
The stator of the rotating electrical machine according to claim 2 is characterized in that a cutout portion extending in the axial direction is formed in the split core.
According to the above means, for example, when joining a plurality of divided cores in an annular shape, the inner surfaces of the notches can be pressed against the jig to position the plurality of divided cores in an annular shape.
[0006]
The stator of the rotating electric machine according to claim 3 is characterized at the notch for welding the split cores extends in the axial direction is formed.
According to the above means, the welding cost is increased and the welding strength between the magnetic plates is increased, so that the mechanical strength of the stator core is increased.
[0007]
The stator of the rotating electrical machine according to claim 4 is formed based on laminating a plurality of first steel plates and a plurality of second steel plates so that the first steel plates and the second steel plates are alternately arranged. A plurality of split cores each having an arc-shaped split yoke and a straight magnetic pole tooth projecting inward from the split yoke, and one end portion in the circumferential direction of each of the plurality of first steel plates A first bent surface having an inverted “<” shape that is recessed toward the magnetic pole teeth side, and the first bent surface on each of the plurality of second steel plates, Is formed at the other end portion in the circumferential direction on the opposite side, and has a second bent surface having an inverted “<” shape that is recessed toward the magnetic pole teeth side, and the plurality of first pieces Each steel plate is located at the other end in the circumferential direction opposite to the first bent surface. A third bent surface formed in a "<" shape and traveling to the opposite side of the magnetic pole teeth, and the second bent surface on each of the plurality of second steel plates. A fourth bent surface that is formed at one end portion in the circumferential direction on the opposite side and that travels to the opposite side of the magnetic pole teeth, and has a “U” shape; and the plurality of split cores A first comb-tooth portion formed at one end in each circumferential direction and having a comb-tooth shape alternately having the first bent surface and the third bent surface; and the plurality of divided cores A plurality of second comb teeth formed in the other circumferential end of each of the first and second comb teeth having the second bent surface and the fourth bent surface alternately, and the plurality of comb teeth Before the adjacent cores are adjacent to each other in the circumferential direction, which are formed by connecting the divided cores to each other. The first comb tooth portion and the second comb tooth portion wrap in the axial direction on the second comb tooth portion, and the first bent surface and the third bent surface are in contact with each other, and It is characterized in that an annular stator core formed by meshing so that the second bent surface and the fourth bent surface are in contact with each other is provided .
According to the above means, the magnetic flux does not enter the circumferential end face of the comb tooth portion at the same time, so that the loss of magnetic flux is further reduced and the magnetic efficiency is further enhanced.
[0008]
According to a fifth aspect of the present invention, when the stator according to the first aspect is manufactured, the first comb tooth portion and the second comb are formed at both ends based on turning the magnetic plate upside down and overlapping the magnetic plate. It is characterized in that a split core having tooth portions is formed.
According to the above means, it is not necessary to punch out two types of magnetic plates having different contour shapes by using separate press machines, so that the press device is simple and small.
[0009]
According to a sixth aspect of the present invention, there is provided a method for manufacturing the stator according to the first aspect. It is characterized in that a split core having two comb teeth is formed.
According to the above means, it is not necessary to punch out two types of magnetic plates having different contour shapes by using separate press machines, so that the press device is simple and small.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. In this embodiment, the present invention is applied to an inner rotor type three-phase DC brushless motor. First, in FIG. 1A, each divided core 1 has an arc-shaped divided yoke 2, a straight magnetic pole tooth 3, and a magnetic pole piece 4. As shown in FIG. The first steel plate 5 and the second steel plate 6 corresponding to the magnetic plate are alternately laminated in the axial direction and mechanically connected (for example, caulking, welding, etc.).
[0011]
As shown in FIG. 5, the first steel plate 5 is punched in a row from the strip-shaped steel plate 7, and at one end in the circumferential direction of the first steel plate 5, as shown in FIG. A linear parallel surface 8 is formed parallel to the first steel plate 5, and a linear inclined surface 9 is formed at the other circumferential end of the first steel plate 5, which is inclined by θ ° in one direction with respect to the center line CL. Yes. The center line CL is a straight line parallel to the magnetic pole teeth 3.
[0012]
The second steel plate 6 is formed on the basis of turning the predetermined steel plate 5 upside down after punching the first steel plate 5 in a row from the strip-shaped steel plate 7, and one end in the circumferential direction of the second steel plate 6. As shown in FIG. 4, a linear inclined surface 10 that is inclined by θ ° in the opposite direction to the inclined surface 9 with respect to the center line CL is formed, and is formed at the other circumferential end of the second steel plate 6. Is formed with a linear parallel surface 8 parallel to the magnetic pole teeth 3.
[0013]
As shown in FIG. 1A, each split core 1 is formed with wrap portions 11 located at both ends in the circumferential direction of the split yoke 2. Each of these lap portions 11 has a triangular shape when viewed in the axial direction, and the lap portion 11 located at one end portion in the circumferential direction of each divided core 1 includes the parallel surface 8 of the first steel plate 5 and the second steel plate 6. The wrap part 11 which has a comb-tooth shape composed of the inclined surface 10 and is located at the other circumferential end of each divided core 1 is an inclined surface 9 of the first steel plate 5 and a parallel surface 8 of the second steel plate 6. Comb-like shape consisting of Note that the wrap portion 11 corresponds to a comb tooth portion.
[0014]
The stator core 12 in FIG. 2 is formed by combining six divided cores 1 in an annular shape, and each lap portion 11 meshes with a lap portion 11 adjacent in the circumferential direction from the axial direction, and laps adjacent in the circumferential direction. The portion 11 is wrapped in the circumferential direction. Laser welding is performed along the axial direction between each set of lap portions 11 meshing in the axial direction, and the six divided cores 1 are held in an annular shape by laser welding.
[0015]
As shown in FIG. 3A, the stator core 12 is formed with a synthetic resin mold layer 13 corresponding to each magnetic pole tooth 3. As shown in FIG. 3 (b), each mold layer 13 includes a rectangular tube-shaped coil winding portion 14 that covers the surface of the magnetic pole teeth 3, and a collar portion that is located on the inner peripheral portion of the coil winding portion 14. 15, an arc-shaped end plate portion 16 covering the upper end surface in the axial direction of the split yoke 2, and an arc-shaped end plate portion 17 covering the lower end surface in the axial direction of the split yoke 2. Is formed on the basis of insert molding in which molten resin is poured into a mold (not shown).
[0016]
A coil 18 is mounted on each magnetic pole tooth 3 from above the coil winding portion 14. Each of the coils 18 is wound around the magnetic pole teeth 3 before the divided cores 1 are combined into an annular shape, and the winding direction is changed from the outer peripheral side to the inner peripheral side as shown in FIG. And it winds in the substantially step shape, reversing for every layer from the inner peripheral side to the outer peripheral side.
[0017]
According to the said Example, the lap | wrap part 11 was formed in the circumferential direction both ends of the split core 1, each lap | wrap part 11 was meshed | engaged from the axial direction to the lap | wrap part 11 adjacent to the circumferential direction, and was wrapped in the circumferential direction. For this reason, since the loss amount of the magnetic flux which flows into the division | segmentation core 1 adjacent to the circumferential direction from the division | segmentation core 1 decreases, magnetic efficiency improves.
[0018]
Further, the end surface of one lap portion 11 of the split core 1 is constituted by the parallel surface 8 of the first steel plate 5 and the inclined surface 10 of the second steel plate 6, and the end surface of the other wrap portion 11 is the first steel plate 5. The inclined surface 9 and the parallel surface 8 of the second steel plate 6. For this reason, since the circumferential wrap amount between the wrap portions 11 increases, the loss amount of magnetic flux flowing from the split core 1 to the split core 1 adjacent in the circumferential direction is further reduced, and the magnetic efficiency is further improved.
[0019]
Moreover, the split core 1 was formed based on turning over the first steel plate 5 and overlapping the first steel plate 5. For this reason, it is not necessary to punch the first steel plate 5 and the second steel plate 6 using separate press machines, so that the press device is simple and small.
[0020]
Next, a second embodiment of the present invention will be described with reference to FIG. Note that the same members as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted, and only different members will be described below. Each divided core 1 is formed with cutout portions 19 and 20 that are positioned in the divided yoke 2 and the magnetic pole piece 4 and extend in the axial direction. Each of the former cutout portions 19 has a semicircular shape that opens on the outer peripheral side, Each of the latter notches 20 has a semicircular shape with an inner peripheral side opened.
[0021]
Each notch 19 and 20 is formed based on laminating | stacking the 1st steel plate 5 and the 2nd steel plate 6 which have a notch, and each division | segmentation core 1 is the inner surface of the notches 19 and 20. Are mechanically connected on the basis of laser welding.
[0022]
According to the above embodiment, the notches 19 and 20 are formed in the split core 1. For this reason, for example, when the plurality of split cores 1 are welded in an annular shape, the inner surface of the notch 19 and the inner surface of the notch 20 can be pressed against a jig, and the plurality of split cores 1 can be positioned in an annular shape. The roundness increases.
Moreover, since the 1st steel plate 5 and the 2nd steel plate 6 were joined based on performing laser welding along the notches 19 and 20, protrusion of a welding part is prevented. At the same time, the welding cost is increased, and the welding strength between the first steel plate 5 and the second steel plate 6 is increased, so that the mechanical strength of the stator core 12 is increased.
[0023]
In the second embodiment, two types of notches 19 and 20 are formed in the split core 1. However, the present invention is not limited to this. For example, one of the notches 19 and 20 is formed. Also good.
Moreover, in the said 2nd Example, although laser welding was performed along the notches 19 and 20, it is not limited to this, For example, you may perform arc welding.
[0024]
Next, a third embodiment of the present invention will be described with reference to FIG. Note that the same members as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted, and only different members will be described below. As shown in FIG. 7B, an inverted “<”-shaped bent surface 21 is formed at one circumferential end of the first steel plate 5, and at the other circumferential end of the first steel plate 5. Is formed with a "<"-shaped bent surface 22. The second steel plate 6 is formed by turning the first steel plate 5 upside down, and a bent surface 22 is formed at one circumferential end of the second steel plate 6. A bent surface 21 is formed at the other circumferential end of 6.
[0025]
As shown in FIG. 7A, each split core 1 is formed with a wrap portion 23 corresponding to a comb tooth portion located at both circumferential ends of the split yoke 2. Each of the wrap portions 23 has a comb-like shape having alternately bent surfaces 21 and 22, meshes with the lap portions 23 adjacent in the circumferential direction from the axial direction, and wraps in the circumferential direction.
[0026]
According to the above embodiment, the circumferential end surface of the wrap portion 23 is constituted by the first bent surface 21 and the second bent surface 22. For this reason, since the magnetic flux does not enter the circumferential end face of the wrap portion 23 at the same time, the loss amount of the magnetic flux is further reduced, and the magnetic efficiency is further increased.
[0027]
In the third embodiment, the bent surfaces 21 and 22 are formed in a smooth bent surface, but the present invention is not limited to this, and as shown in FIG. 8 showing the fourth embodiment of the present invention, You may form in the shape of a linear bending surface.
[0028]
Moreover, in the said 1st-4th Example, although the 1st steel plate 5 was punched in 1 row from the strip | belt-shaped steel plate 7, it is not limited to this, For example, 5th Example of this invention is shown. As shown in FIG. 9, the magnetic teeth 3 face each other and are punched into even rows (for example, two rows), and the same contour as the second laminated plate 6 is obtained by changing the direction of the first steel plate 5 in the upper row by 180 °. After making it into a shape, it is good to overlap with the 1st steel plate 5 of a lower row, and to form the split core 1. FIG. Even in this configuration, there is no need to punch out the first steel plate 5 and the second steel plate 6 using separate press machines, so that the press device is simple and small.
[0029]
Moreover, in the said 1st-5th Example, although the 1st steel plate 5 and the 2nd steel plate 6 were laminated | stacked alternately one by one, it is not limited to this, A plurality (for example, 2 sheets) You may laminate | stack alternately.
[0030]
【The invention's effect】
As is clear from the above description, the stator of the rotating electrical machine of the present invention has the following effects.
According to the means of the first aspect, the comb teeth of the split core are meshed with the comb teeth adjacent in the circumferential direction from the axial direction and are wrapped in the circumferential direction. For this reason, since the loss amount of the magnetic flux which flows into the division core adjacent to the circumferential direction from a division core decreases, magnetic efficiency improves. And the circumferential direction end surface of the comb-tooth part was comprised from the parallel surface and the inclined surface. For this reason, since the circumferential wrap amount between the comb teeth is increased, the loss amount of the magnetic flux flowing from the divided core to the divided core adjacent in the circumferential direction is further reduced, and the magnetic efficiency is further improved.
[0031]
According to the means of the second aspect , the notch is formed in the split core. For this reason, for example, when joining a plurality of divided cores in an annular shape, the inner surface of the notch can be pressed against a jig to position the plurality of divided cores in an annular shape.
[0032]
According to the third aspect of the present invention, since welding is performed along the cutout portion of the split core, the projection of the welded portion is prevented. At the same time, the welding allowance is increased and the welding strength between the magnetic plates is increased, so that the mechanical strength of the stator core is increased.
According to the means of the fourth aspect, the circumferential end surface of the comb tooth portion is composed of a plurality of types of bent surfaces. For this reason, the magnetic flux does not enter the circumferential end surface of the comb tooth portion at the same time, so that the loss of magnetic flux is further reduced and the magnetic efficiency is further enhanced.
[0033]
According to the means of the fifth aspect, the split core is formed based on turning the magnetic plate upside down and overlapping the magnetic plate. For this reason, it is not necessary to punch out two types of magnetic plates having different contour shapes using separate press machines, so that the press device is simple and small.
According to the means of the sixth aspect, the split core is formed on the basis of reversing the direction of the magnetic plate and overlapping the magnetic plate. For this reason, it is not necessary to punch out two types of magnetic plates having different contour shapes using separate press machines, so that the press device is simple and small.
[Brief description of the drawings]
FIG. 1 is a view showing a first embodiment of the present invention (a is a plan view showing a split core, and b is a cross-sectional view taken along line XX).
FIG. 2 is a plan view showing a stator core. FIG. 3A is a plan view showing the stator core in a coiled state, and FIG. 2B is a cross-sectional view taken along line XX. Fig. 5 is a plan view showing a second steel plate. Fig. 5 is a diagram showing a punched state of the first steel plate. Fig. 6 is a diagram showing a second embodiment of the present invention (plan view showing a split core).
FIG. 7 is a view showing a third embodiment of the present invention (a is a plan view showing a split core, and b is a plan view showing a first steel plate and a second steel plate).
FIG. 8 is a view showing a fourth embodiment of the present invention (a is a plan view showing a split core, and b is a plan view showing a first steel plate and a second steel plate).
FIG. 9 is a view showing a fifth embodiment of the present invention (plan view showing a punched state of the first steel plate).
[Explanation of symbols]
1 is a split core, 3 is a magnetic tooth, 5 is a first steel plate (magnetic plate), 6 is a second steel plate (magnetic plate), 8 is a parallel surface, 9 and 10 are inclined surfaces, and 11 is a lap portion (comb) (Tooth portion), 12 is a stator core, 19 and 20 are notches, 21 and 22 are bent surfaces, and 23 is a wrap portion (comb portion).

Claims

A plurality of first steel plates and a plurality of second steel plates are formed on the basis of stacking the first steel plates and the second steel plates alternately so as to be divided into arcs. A plurality of split cores having straight magnetic pole teeth protruding from the yoke and the split yoke to the inner peripheral side;
Each of the plurality of first steel plates is formed at one end in the circumferential direction, and has a first parallel surface that forms a straight line parallel to the extending direction of the magnetic pole teeth,
Each of the plurality of second steel plates is formed at the other end portion in the circumferential direction opposite to the first parallel surface, and is formed with respect to the extending direction of the magnetic pole teeth. A second parallel surface forming a parallel straight line;
Each of the plurality of first steel plates is formed at the other end in the circumferential direction opposite to the first parallel surface, and the outer peripheral side of the second parallel surface A first inclined surface that forms a linear shape that is inclined with respect to the second parallel surface with respect to the starting point, and that is inclined so as to approach the magnetic pole teeth from the outer peripheral portion toward the inner peripheral portion;
Each of the plurality of second steel plates is formed at one end in a circumferential direction opposite to the second parallel surface, and is formed on the outer peripheral side of the first parallel surface. First, the first parallel surface is inclined with respect to the first parallel surface at the same angle as the first inclined surface, and is inclined so as to approach the magnetic pole teeth from the outer peripheral portion toward the inner peripheral portion. Two inclined surfaces;
Each of the plurality of divided cores is formed at one end in the circumferential direction, has a comb-like shape having the first parallel surface and the second inclined surface alternately, and has a triangular view in the axial direction. A first comb tooth portion having a shape;
Each of the plurality of divided cores is formed at the other circumferential end, and has a comb-like shape having the first inclined surface and the second parallel surface alternately, and has an axial view. A second comb tooth portion having a triangular shape;
The plurality of divided cores are connected to each other, and each of the plurality of first comb teeth is circumferentially adjacent to the second comb teeth and the first comb teeth and The second comb teeth wrap in the axial direction, the first parallel surface and the second inclined surface are in contact with each other, and the first inclined surface and the second parallel surface are in contact with each other. A stator for a rotating electrical machine, comprising an annular stator core that is meshed so as to come into contact with each other.

The stator for a rotating electrical machine according to claim 1, wherein each of the plurality of divided cores is formed with a notch extending in the axial direction .

2. The stator for a rotating electrical machine according to claim 1, wherein each of the plurality of divided cores is formed with a notch for welding extending in an axial direction .

A plurality of first steel plates and a plurality of second steel plates are formed on the basis of stacking the first steel plates and the second steel plates alternately so as to be divided into arcs. A plurality of split cores having straight magnetic pole teeth protruding from the yoke and the split yoke to the inner peripheral side;
Each of the plurality of first steel plates is formed at one end in the circumferential direction, and has a first bent surface having an inverted “<” shape that is recessed toward the magnetic pole teeth side,
Each of the plurality of second steel plates is formed to be positioned at the other end in the circumferential direction opposite to the first bent surface, and is recessed toward the magnetic pole teeth side. A second bent surface in the shape of a letter;
Each of the plurality of first steel plates is formed at the other end in the circumferential direction opposite to the first bent surface, and travels to the opposite side to the magnetic pole teeth. A third bent surface having a "<"shape;
Each of the plurality of second steel plates is formed at one end in a circumferential direction opposite to the second bent surface, and travels to the opposite side to the magnetic teeth. A fourth bent surface having a "<" shape,
A first comb tooth portion formed at one end portion in the circumferential direction of each of the plurality of divided cores, wherein the first comb tooth portion has a comb tooth shape having the first bent surface and the third bent surface alternately. When,
Second comb teeth formed at the other circumferential end of each of the plurality of divided cores and having a comb-teeth shape alternately having the second bent surface and the fourth bent surface And
The plurality of divided cores are connected to each other, and each of the plurality of first comb teeth is circumferentially adjacent to the second comb teeth and the first comb teeth and The second comb teeth wrap in the axial direction and the first bent surface and the third bent surface are in contact with each other, and between the second bent surface and the fourth bent surface There you comprising the annular stator core composed by mesh in contact rotary electric machine stator.

The method of manufacturing a stator according to claim 1,
A stator manufacturing method comprising: forming a split core having a first comb tooth portion and a second comb tooth portion at both ends based on turning over a magnetic plate and overlapping the magnetic plate.

The method of manufacturing a stator according to claim 1,
A method of manufacturing a stator, comprising forming a split core having first and second comb teeth at both ends based on reversing the direction of a magnetic plate and overlapping the magnetic plate .