JP4705947B2 - Stator manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a stator.

Generally, an inner rotor type motor is configured such that a rotor (rotor) is arranged in a space formed inside a cylindrical stator (stator) and the rotor is rotatable with respect to the stator. Yes (see, for example, Patent Document 1). A coil is wound around the teeth portion of the stator, and distributed winding and concentrated winding are known as the winding method of the coil.
As shown in FIG. 12, the stator of Patent Document 1 has two slots (slot numbers 1 and 6) in which the first winding U1 is housed for the purpose of reducing the protruding height of the coil end portion of the stator. ) Between the two slots in which the first winding U1 is stored, and the second winding W1 having a phase different from that of the first winding U1 is stored in the slot (slot number 3). 2) accommodates a third winding W6 having the same phase as the second winding, and the second winding W1 and the third winding W6 are the first (winding W6) at the coil end portion. The distributed windings are arranged such that the other winding (winding W1) is positioned on the inner peripheral side of the first winding U1.
JP 2002-44893 A

  By the way, although the distributed winding used in the stator of Patent Document 1 is easy to maintain high torque density performance, the winding method of the coil is complicated compared to the concentrated winding, and particularly in the downsized inner rotor type stator, The distance between adjacent teeth portions is close (the slot is narrow), and it takes a very long time to wind the coil by the method described in Patent Document 1, and the production efficiency is poor.

  Therefore, the present invention has been made in view of the above circumstances, and provides a method for manufacturing a stator capable of improving production efficiency.

In order to solve the above-described problems, the invention described in claim 1 includes a step of arranging a plurality of stator core pieces (for example, the core pieces 11 in the embodiment) in a strip shape, and the adjacent stator core pieces. A step of inserting a winding (for example, the coil 20 in the embodiment) into a slot portion (for example, the slot portion 19 in the embodiment) formed therebetween, and a step of deforming the strip-shaped stator core piece into a cylindrical shape After making the stator core piece cylindrical, the windings straddling both ends of the band-like stator core piece are inserted into the slot portion to form a stator (for example, the stator 1 in the embodiment). a process and, stator manufacturing method provided with, the stator core pieces, the connecting portion connecting the stator core pieces adjacent to each other (e.g., the first connecting portion 21 in the embodiment, the second Connecting part 22) is shaped Are, the connecting portion is characterized by coupling the stator core pieces together linked with rotatable state.

  The invention described in claim 2 is characterized in that the winding is inserted into a pair of the slot portions separated by a predetermined interval.

  The invention described in claim 3 is characterized in that the winding is inserted into the pair of slot portions in a state of being wound in a ring shape in advance.

According to a fourth aspect of the present invention, the stator core piece includes a yoke (for example, the yoke 13 in the embodiment), a tooth (for example, the tooth 15 in the embodiment), and a tip portion (for example, the tip portion 17 in the embodiment). The first connecting portion (for example, the first connecting portion 21 in the embodiment) protruding from one end portion of the outer periphery of the yoke is configured by laminating flat steel plates (for example, the flat steel plate 51 in the embodiment) having The 2nd connection part (for example, 2nd connection part 22 in embodiment) protruded from the other end part is formed, and the stator core piece is a flat steel plate having the first connection part, and the second connection. a flat steel plate having a part that are alternately stacked, the adjacent stator core pieces, are characterized in that facing the slot portion in a state of overlapping in a plan view .

The invention described in claim 5 is characterized in that the windings of a plurality of phases forming the rotating magnetic field of the motor are all formed in the same shape.

According to the first aspect of the present invention, since the slot portion can be secured large by arranging the stator core pieces in a band shape, the winding can be easily inserted into the slot portion. In addition, after the winding is attached, the stator core piece is deformed into a cylindrical shape, and the windings (windings not inserted in the slot portion) disposed at both ends of the belt-like stator core piece are slot portions. The stator can be formed by inserting it into. Therefore, the production efficiency of the stator can be improved.
In addition, since the adjacent stator core pieces are connected to each other by the connecting portion, it is possible to prevent occurrence of misalignment between the stator core pieces being arranged in a band shape and being deformed into a cylindrical shape. . Therefore, there is an effect that the stator core piece can be accurately deformed from the strip shape to the cylindrical shape.

  According to the second aspect of the present invention, since the high torque density performance can be maintained by making the windings distributed, there is an effect that a high-performance motor stator can be manufactured.

  According to the invention described in claim 3, since the winding is wound in advance to form the ring, the winding can be attached by simply inserting the winding formed in a ring shape into the slot portion. Therefore, the production efficiency can be improved as compared with the case where the winding is wound around the slot portion after preparing the stator core piece.

  According to the invention described in claim 4, since a gap continuous in the stacking direction of the stator core pieces is not formed between adjacent stator core pieces in the slot portion, when the winding is inserted into the slot portion, It is possible to prevent a part of the winding from being sandwiched in the gap and being damaged. In addition, since the winding is not sandwiched, there is an effect that when the stator core piece is deformed into a cylindrical shape, it can be reliably deformed into a cylindrical shape.

According to the fifth aspect of the present invention, for example, when manufacturing a three-phase motor including a U phase, a V phase, and a W phase, windings corresponding to the respective phases can be manufactured in the same process. Therefore, the production efficiency can be improved.

(First embodiment)
Next, a first embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a plan view of the stator. In FIG. 1, the coil 20 is shown in a sectional view on the surface of the stator core 10. As shown in FIG. 1, the stator 1 includes a stator core 10 configured in a cylindrical shape, and a coil 20 wound around a tooth 15 of the stator core 10. In a space formed at the center of the cylindrical shape of the stator 1, a rotor (not shown) is rotatably arranged.

  FIG. 2 is a plan view of the stator core. As shown in FIG. 2, the stator core 10 is configured by connecting a plurality of core pieces 11 in a cylindrical shape. The stator core 10 includes a yoke 13 that forms a cylindrical outer periphery, teeth 15 that protrude from the yoke 13 toward the center of the cylinder, and a tip 17 that forms the tip of the teeth 15. In addition, a space (hereinafter referred to as a slot 19) is formed between adjacent teeth 15. Then, by arranging the coil 20 wound around the teeth 15 in the slot 19, the stator 1 is formed as described above.

  FIG. 3 is a plan view of the core piece 11. As shown in FIG. 3, the core piece 11 is configured by laminating a flat steel plate 51 on which a yoke 13, a tooth 15, and a tip end portion 17 are formed. The flat steel plate 51 constituting the core piece 11 can be easily manufactured by press molding. Here, one tooth 15 is formed on one core piece 11. That is, the core piece 11 is divided for each tooth 15.

  The yoke 13 is formed with a first connecting portion 21 protruding from one end portion of the outer periphery or a second connecting portion 22 protruding from the other end portion. In other words, the flat steel plate 51 constituting the core piece 11 has a connection portion formed at one end portion and a connection portion formed at the other end portion, and these are alternately laminated to constitute the core piece 11. Yes. By doing in this way, the 1st connection part 21 is connected with the 2nd connection part 22b of the adjacent core piece 11b, and the 2nd connection part 22 is connected with the 1st connection part 21a of the adjacent core piece 11a. Moreover, the 1st connection part 21 and the 2nd connection part 22 are connected so that rotation is possible. For example, a through hole 31 is formed in the first connecting part 21 and the second connecting part 22, and a pin can be inserted into the through hole 31 so as to be hinge-coupled.

  Further, on both side portions of the yoke 13 in the circumferential direction (both side portions between the outer peripheral portion and the inner peripheral portion), a concave portion 24 is formed on one side portion 23, and the concave portion 24 is fitted on the other side portion 25. A convex portion 26 is formed. The concave portion 24 and the convex portion 26 are separated when the adjacent core pieces 11 are strip-shaped, and are configured to be fitted when the core pieces 11 are deformed from a strip shape to a cylindrical shape.

Next, a procedure for connecting the core pieces 11 to form the stator 1 will be described.
FIG. 4 is a partial plan view of the core piece in a band shape. As shown in FIG. 4, a plurality of flat steel plates 51 are laminated and joined to form a core piece 11 having a desired thickness. A plurality of core pieces 11 are prepared and arranged in a strip shape in the same direction. And the adjacent core pieces 11 are connected. At this time, the 1st connection part 21 of the one core piece 11 and the 2nd connection part 22 of the other core piece 11 are connected so that rotation is possible among the adjacent core pieces 11. FIG. In order to connect the adjacent core pieces 11, the second connection formed in the stacking direction of the other core piece 11 in the gap between the first connecting portions 21 formed in the stacking direction of the one core piece 11. The part 22 is inserted, and then connected by inserting a pin into the through hole 31.

  After all the core pieces 11 are connected, the insulating paper 29 is disposed along the side surface of the slot 19. After the insulating paper 29 is disposed, the coil 20 is disposed in the slot 19. Specifically, as shown in FIG. 5, a coil (coil 20) in which a conducting wire is wound so as to form a plurality of rings 33 by a winding device (not shown) is manufactured. At this time, both ends of the conducting wire are extended from the ring so that they can be connected to the power supply terminal and the ground terminal. In the case of a three-phase motor, three coils 20 are manufactured. In the present embodiment, the three coils 20 are all manufactured in the same shape.

  FIG. 6 is an explanatory view showing a method of inserting the coil into the slot portion. As shown in FIG. 6, the three coils 20 constitute a three-phase U phase, V phase, and W phase. In the present embodiment, the stator core 10 is configured using 48 core pieces 11. That is, 48 slots 19 are formed. Here, the coil 20a constituting the U phase is formed with eight rings (rings U1 to U8). Similarly, rings V1 to V8 are formed in the coil 20b constituting the V phase, and rings W1 to W8 are formed in the coil 20c constituting the W phase. These rings are formed in such a size that they can be inserted into two slots 19 spaced apart from each other. Then, after the coil 20 is manufactured, the coil 20 is inserted into the slot 19 of the stator core 10.

  Specifically, U-phase coil 20a inserts ring U1 into slot 19 with slot number 1 and slot number 6, inserts ring U2 into slot 19 with slot number 7 and slot number 12, and so on. Ring U8 is inserted into slot 19 with slot number 43 and slot number 48. The V-phase coil 20b has the ring V1 inserted into the slot 19 with the slot number 45 and the slot number 2, the ring V2 inserted into the slot 19 with the slot number 3 and the slot number 8, and the slot number 39 and the like. The ring V8 is inserted into the slot 19 with the slot number 44. Further, the W-phase coil 20c inserts the ring W1 into the slot 19 with the slot number 47 and the slot number 4, inserts the ring W2 into the slot 19 with the slot number 5 and the slot number 10, and similarly with the slot number 41 and The ring W8 is inserted into the slot 19 with the slot number 46.

Next, a procedure for inserting the coil 20 into the slot 19 will be described. In the following description, the slot 19 will be described using only the slot number.
FIG. 7 is a perspective view showing a coil arrangement state, and FIG. 8 is a plan view of the core piece in a cylindrical shape. In the present embodiment, the coil is inserted into the strip-shaped core piece before being cylindrical, but here, description will be made with reference to FIG. 8 showing the core piece after being cylindrical.
As shown in FIGS. 7 and 8, the ring V1 of the coil 20b constituting the V phase is inserted into the slot number 2. At this time, the other side of ring V1 (part A in FIG. 6) is not inserted into slot number 45. Next, the ring W1 of the coil 20c constituting the W phase is inserted into the slot number 4. At this time, the other of the rings W1 (B portion in FIG. 6) is not inserted into the slot number 47. Next, the ring U1 of 20a constituting the U phase is inserted into the slot number 6. At this time, the other ring U1 is temporarily inserted into slot number 1.

  Next, the ring V2 of the V-phase coil 20b is inserted so as to span the slot number 3 and the slot number 8. Similarly, after inserting the ring W2 of the W-phase coil 20c so as to span the slot number 5 and the slot number 10, the ring U2 of the U-phase coil 20a is inserted so as to span the slot number 7 and the slot number 12. To do. By repeating this procedure, V 3 → W 3 → U 3 → V 4 →... → V 8 → W 8 → U 8 are inserted into the slots 19. When the coil 20 is thus inserted into the slot 19, the coil 20 is disposed so as to be inclined between the two slots 19 as shown in FIG. 8. As shown in FIG. 6, for example, the winding direction of the conducting wire of slot number 6 and the winding direction of the conducting wire of slot number 7 are inserted in the same direction. Thus, the conducting wire of the same phase inserted in the adjacent slot 19 is inserted so that the winding direction of the conducting wire becomes the same direction.

  In this way, the band-shaped core piece 11 is deformed into a cylindrical shape with the A part of the ring V1 and the B part of the ring W1 not inserted into the slot 19, and the core pieces 11 at both ends in the band-like form are connected to each other. As shown in FIG. Then, if necessary, the ring U1 temporarily inserted into the slot number 1 is once removed, and the ring V1 (part A in FIG. 6) of the V-phase coil 20b not inserted into the slot 19 is set to the slot number 45. insert. Thereafter, the ring W1 (B portion in FIG. 6) of the W-phase coil 20c is inserted into the slot number 47. When the coils 20 are inserted into all the slots 19, the stator 1 is inserted into a core ring (motor outer cylinder) (not shown). And after adjusting a conducting wire so that each coil 20a, 20b, 20c inserted in the slot 19 does not loosen, the conducting wire extended from the both ends of each coil 20a, 20b, 20c is made into U phase, V phase, and Connect to the W-phase power supply terminal and ground terminal.

  According to the present embodiment, a step of arranging a plurality of core pieces 11 in a strip shape, a step of inserting a coil 20 into a slot 19 formed between adjacent core pieces 11, and a belt-like core piece 11 in a cylindrical shape After forming the core piece 11 into a cylindrical shape, the coil 20 (A part and B part in FIG. 6) straddling both ends of the belt-like core piece 11 is inserted into the slot 19 to form the stator 1. And a step of performing.

More specifically, a step of forming the core piece 11 having the yoke 13 and the teeth 15, and a plurality of core pieces 11 are arranged in parallel, and a belt-like shape having a slot 19 between the teeth 15 of the adjacent core pieces 11. A step of forming an array of core pieces 11 and an end coil (ring V1) straddling both sides of the array of core pieces 11 while inserting the coil 20 over a pair of slots 19 spaced at a predetermined interval. , W1) is inserted into only one slot 19 of the pair of slots 19, and the array of strip-shaped core pieces 11 is deformed into a cylindrical shape to join both ends of the core pieces 11, A step of forming the stator 1 and a second insertion step of inserting the end coils (rings V1 and W1) into the other slot 19 of the pair of slots 19 are provided.
The one slot 19 into which the end coil is inserted in the first insertion step is a slot in which the end coil is disposed on the outer peripheral side of the stator 1 with respect to the other coil 20, and the end coil in the second insertion step. The other slot 19 into which is inserted is a slot 19 in which the end coil is disposed on the inner peripheral side of the stator 1 with respect to the other coil 20.

  By arranging the core pieces 11 in a band shape in this way, the slot 19 can be secured large, so that the coil 20 can be easily inserted into the slot 19. For this reason, the coil 20 (ring 33) can be formed to the minimum necessary size, and the winding span can be lowered. In addition, after inserting the coil 20, the core piece 11 is deformed into a cylindrical shape, and the coils 20 (rings V <b> 1, W <b> 1) disposed at both ends of the belt-like core piece 11 are inserted into the slots 19, so Can be formed. Therefore, the production efficiency of the stator 1 can be improved.

Further, the coil 20 is constituted by distributed winding in which the coil 20 is wound between the slots 19 spaced apart by a predetermined interval, and the same coil 20 is wound around the slot 19 adjacent to the outside of the slot 19.
Since the coil 20 is distributed winding as described above, high torque density performance can be maintained, and therefore the high-performance motor stator 1 can be manufactured.

In addition, a step of forming a ring 33 (coil 20) having a size corresponding to the slot 19 by winding a conducting wire in advance is provided.
Thus, since the conducting wire is wound in advance to form the ring 33 (coil 20), the coil 20 can be attached simply by inserting the conducting wire formed in a ring shape into the slot 19. Therefore, the production efficiency can be improved as compared with the case where the winding is wound around the slot 19 after the core piece 11 is prepared.

Furthermore, the 1st connection part 21 and the 2nd connection part 22 which connect the core pieces 11 adjacent to the core piece 11 were formed.
By configuring in this way, the adjacent core pieces 11 are connected by the first connecting portion 21 and the second connecting portion 22 until the core pieces 11 are arranged in a band shape and deformed into a cylindrical shape. Therefore, the occurrence of displacement can be prevented. Therefore, the core piece 11 can be accurately deformed from a strip shape to a cylindrical shape.

Then, the coils 20 (20a, 20b, 20c) constituting the U phase, the V phase, and the W phase forming the rotating magnetic field of the motor were all formed in the same shape.
Therefore, when manufacturing a three-phase motor composed of a U phase, a V phase, and a W phase, the coil 20 (20a, 20b, 20c) corresponding to each phase can be manufactured in the same process. Therefore, production efficiency can be improved.

(Second embodiment)
Next, a second embodiment of the present invention will be described with reference to FIGS. The present embodiment is different from the first embodiment only in the configuration of the core piece, and the other components are substantially the same as those in the first embodiment. Description is omitted.

  FIG. 9 is a plan view of the core piece 111. As shown in FIG. 9, the core piece 111 is configured by laminating a plurality of flat steel plates 151 on which yokes 13, teeth 15, and tip portions 17 are formed. Here, one tooth 15 is formed on one core piece 111. That is, the core piece 111 is divided for each tooth 15. The flat steel plate 151 constituting the core piece 111 can be easily manufactured by press molding.

10 is a cross-sectional view taken along line AA in FIG. As shown in FIG. 10, the core piece 111 is formed by laminating a plurality of flat steel plates 151 and joining them to have a desired thickness. At this time, they are laminated so that the front and back surfaces of the flat steel plates 151 adjacent (laminated) vertically are reversed.
Returning to FIG. 9, the yoke 13 has a first connecting portion 121 formed at one end near the outer periphery. For example, the 1st connection part 121 is comprised with a through-hole, and is connected with the adjacent core piece 111 so that rotation is possible by inserting a pin in a through-hole.

  A first cylindrical contact portion 128 is formed near the boundary between the yoke 13 and the tooth 15 on the side where the first connecting portion 121 is formed. Further, a second cylindrical time contact portion 138 is formed in the vicinity of the boundary between the yoke 13 and the opposite tooth 15 where the first cylindrical time contact portion 128 is formed. The outer shape of the second cylindrical contact portion 138 is formed in substantially the same shape as the first cylindrical contact portion 128. In the state where the core piece 111 is connected in a band shape, the first cylindrical contact portion 128 and the second cylindrical contact portion 138 are configured to be separated from each other, and the core piece 111 is connected in a cylindrical shape. In the state, the first cylindrical contact portion 128 and the second cylindrical contact portion 138 are configured to contact each other.

  Further, since the flat steel plates 151 constituting the core piece 111 are alternately laminated so that the front and back surfaces are reversed, when the plurality of core pieces 111 are connected in a band shape, an overlapping portion 139 is formed in plan view.

  11 is a cross-sectional view taken along line BB in FIG. As shown in FIG. 11, when the core pieces 111 are connected in a strip shape, an overlapping portion 139 is formed in the stacking direction of the core pieces 111. Even if the coil 20 is inserted into the slot 19 due to the overlapping portion 139, the coil 20 can be caught between the first cylindrical contact portion 128 and the second cylindrical contact portion 138 and be damaged. It can be prevented.

According to the present embodiment, the adjacent core pieces 111 are configured to face the slot 19 in an overlapped state in plan view (so that the overlapping portion 139 is formed).
Due to such a configuration, a gap continuous in the stacking direction of the core pieces 111 is not formed between the adjacent core pieces 111 in the slot 19. Therefore, when the coil 20 is inserted into the slot 19, it can be prevented that a part of the coil 20 is sandwiched in the gap and damaged. In addition, since the coil 20 is not sandwiched, when the core piece 111 is deformed into a cylindrical shape, it can be reliably deformed into a cylindrical shape.

The technical scope of the present invention is not limited to the above-described embodiment, and includes various modifications made to the above-described embodiment without departing from the spirit of the present invention. That is, the specific structure and configuration described in the embodiment are merely examples, and can be changed as appropriate.
For example, in this embodiment, the case where three-phase coils are sequentially inserted into the slot portion has been described. However, after all the U-phase coils are initially inserted into the slot portion, the V-phase coil is inserted. May be inserted into the slot portion, and then all the W-phase coils may be inserted into the slot portion.

It is a top view of the stator in the embodiment of the present invention. It is a top view of the stator core in the embodiment of the present invention. It is a top view of the core piece in 1st embodiment of this invention. It is a partial top view at the time of the strip | belt shape of the core piece in 1st embodiment of this invention. It is explanatory drawing which shows the structure of the coil in embodiment of this invention. It is explanatory drawing which shows the insertion method to the slot part of the coil in embodiment of this invention. It is a perspective view which shows the arrangement | positioning state of the coil in 1st embodiment of this invention. It is a schematic plan view at the time of the cylindrical shape of the core piece in 1st embodiment of this invention. It is a top view of the core piece in 2nd embodiment of this invention. It is sectional drawing which follows the AA line of FIG. It is sectional drawing which follows the BB line of FIG. It is a top view of the conventional stator.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Stator (stator) 11, 111 ... Core piece (stator core piece) 19 ... Slot (slot part) 20 ... Coil (winding) 21, 121 ... 1st connection part (connection part) 22,122 ... 1st 2 connection part (connection part)

Claims (5)

A step of arranging a plurality of stator core pieces in a strip shape;
Inserting a winding into a slot formed between adjacent stator core pieces;
Transforming the band-shaped stator core piece into a cylindrical shape;
After the stator core pieces into a cylindrical shape, the manufacture of the stator with a step, the forming the stator by inserting the winding across the two ends of the band-shaped stator core pieces in the slot A method ,
The stator core piece is formed with a connecting portion that connects the adjacent stator core pieces, and the connecting portion connects the connected stator core pieces in a rotatable state. A manufacturing method of a featured stator.   The method of manufacturing a stator according to claim 1, wherein the winding is inserted into a pair of the slot portions spaced apart from each other by a predetermined interval.   3. The method of manufacturing a stator according to claim 2, wherein the winding is inserted into the pair of slot portions while being wound in a ring shape in advance. The stator core piece is formed by laminating a yoke, a tooth, and a flat steel plate having a tip, and the yoke has a first connection portion protruding from one end of the outer periphery or a second connection protruding from the other end. Part is formed,
The stator core pieces are laminated alternately with flat steel plates having the first connecting portions and flat steel plates having the second connecting portions,
The method for manufacturing a stator according to claim 1, wherein the adjacent stator core pieces face the slot portion in a state of being overlapped in a plan view.   5. The stator manufacturing apparatus according to claim 1, wherein all of the windings of a plurality of phases forming a rotating magnetic field of a motor are formed in the same shape.

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