JP4890375B2 - Manufacturing method of stator of rotating electric machine - Google Patents

Description

This invention relates to a manufacturing method of the stay other configured electric rotating machine by laminating magnetic plate material.

  Conventionally, as shown in Patent Document 1 (for example, refer to FIG. 7 of Patent Document 1) and Patent Document 2 (for example, refer to FIG. 8 and FIG. 9 of Patent Document 2), a sheet-shaped core member punched from a steel plate is laminated. A stator structure for a rotating electrical machine is known in which after winding a winding, the belt-shaped core member is deformed into an annular shape and both ends are joined by welding.

  Here, as shown in Patent Document 3, the core member has an insulating film formed on the front and back surfaces thereof. By forming insulating coatings on the front and back surfaces of the core member, the laminated core members are insulated from each other, and the generation of eddy currents can be suppressed even when an alternating magnetic field is generated. Therefore, energy loss of the rotating electrical machine due to heat generation of the core member can be reduced.

JP-A-9-191588 Japanese Patent Laid-Open No. 11-346447 JP 2005-323456 A

  If the insulation film is coated on the front and back surfaces of the core member as described above, bubbles are generated from the impurities contained in the insulation film when the end of the core member is welded after the core member is deformed into an annular shape. There was a problem that the strength of the welded portion was impaired.

  When the laminated core member is attached to the stator frame, the load applied to the welded portion of the core member is small because an external load is applied to the stator frame. However, when the core member is not attached to the stator frame, the external load is directly applied to the core member, and a large load is applied to the welded portion.

  And if bubbles exist in the welded portion, there arises a problem that the welded portion is damaged by a large load repeatedly applied.

  This invention was made in order to solve the above problems, and it aims at improving the intensity | strength of the welding part of a core member.

A method of manufacturing a stator for a rotating electrical machine according to the present invention includes a step of sequentially punching a plurality of magnetic plate materials in a shape in which a plurality of core pieces are linearly connected through thin-walled portions in a longitudinal direction of the steel plate from a steel plate, A step of forming a stator core by laminating a plurality of the magnetic plates, and a step of bending the thin portion of the magnetic plate to make the stator core annular and joining both ends of the stator core by welding. The prepared steel plate has a line-shaped non-insulating coating portion extending in the longitudinal direction of the steel plate at a position corresponding to each end portion of the plurality of magnetic plates to be punched, and the insulating coating other than the non-insulating coating portion Is formed.

  According to the present invention, since the insulating coating is not formed on the welded portion of the magnetic plate material, and the insulating coating is formed other than the welded portion of the magnetic plate material, the weld strength of the welded portion can be improved, and the magnetic field that is the magnetic flux passage is also provided. The ratio of the cross-sectional area of the plate material can be increased, and the performance of the rotating electrical machine can be improved.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

Embodiment 1 FIG.
1 is a plan view showing the configuration of a stator of a rotating electrical machine according to Embodiment 1 of the present invention, FIG. 2 is a view showing a process of forming the magnetic plate material of this embodiment by press punching, and FIG. 3 is formed by FIG. FIG. 4 is a plan view showing a state in which the magnetic plate material shown in FIG. 3 is wound, and FIG. 5 is a plan view showing the thin plate connecting portion of the magnetic plate material of the present embodiment. It is sectional drawing which shows this structure.

  In the figure, the first magnetic plate 3 is formed by connecting a plurality of core pieces 3a through thin portions 3b, and the second magnetic plate 4 is formed by connecting each core piece 4a through thin portions 4b. Is formed. The planar shape of the thin portion 3b of the first magnetic plate member 3 and the planar shape of the thin portion 4b of the second magnetic plate member 4 are bilaterally symmetric, and the first and second magnetic plate members 3 and 4 are laminated alternately. Thus, the stator core 6 is configured. As shown in FIG. 5, the edge portions of the core pieces 3a and 4a facing each other with the thin-walled portions 3b and 4b interposed therebetween are alternately overlapped. And as shown in FIG. 4, the coil | winding 5 is wound by each core piece 3a, 4a of the stator core 6 with which the 1st and 2nd magnetic board | plate materials 3 and 4 were laminated | stacked.

  As shown in FIG. 1, the stator core 6 is formed in an annular shape by bending the thin portions 3 b and 4 b of the magnetic plate members 3 and 4. Both end portions of the stator core 6 are brought into contact with each other at the contact portion 100 and welded to form the stator 7 of the rotating electrical machine.

  In the present embodiment, as shown in FIG. 1, a non-insulating coating in which an insulating coating is not formed in the vicinity of the abutting portions 100 on the front and back surfaces of the magnetic plates 3 and 4, that is, in the encircled dotted line portion in FIG. Part 101 is formed. An insulating coating is formed on portions other than the vicinity of the contact portion 100 of each of the magnetic plates 3 and 4, that is, on the portion other than the non-insulating coating portion 101 of the encircled dotted line in FIG. Here, the insulating film is made of an organic material or an inorganic material.

  Next, a method for manufacturing the stator of the rotating electrical machine of the first embodiment configured as described above will be described. In FIG. 2, first, a steel plate 106 for punching out the magnetic plate materials 3 and 4 is prepared by a press machine. The steel plate 106 is coated with an insulating coating on the front and back surfaces, but a line-shaped non-insulating coating portion 107 having no insulating coating is provided at locations corresponding to both ends of each of the magnetic plates 3 and 4 of the steel plate 106. ing. Such a steel plate 106 without a partial insulating coating can be prepared by coating the entire surface of the steel plate 106 with an insulating coating in advance and then removing only the non-insulating coating 107. The insulating film is removed by a method such as scraping, chemical change by chemicals, carbonization by heating and wiping. In this case, it is necessary to remove the insulating coating on both the front and back surfaces of the steel plate 106.

  In FIG. 2, the example in which the line-shaped non-insulating coating portion 107 is provided on the steel plate 106 is shown. However, as shown in FIG. 6, as shown in FIG. Further, a non-insulating film portion 108 in which no insulating film exists may be provided.

  Alternatively, the steel sheet 106 having the insulating film formed on the entire surface may be put into a press machine, and the insulating film may be removed by a coating removing device installed in the press machine.

  Next, at the position indicated by the arrow A in FIG. 2, as a first stage of processing the first magnetic plate material 3, the portion indicated by hatching in the drawing is press-punched to form the periphery of the thin portion 3b. Further, at the position indicated by the arrow B, as the first stage of processing the second magnetic plate material 4, the periphery of the thin portion 4b is formed by press punching a portion indicated by hatching in the drawing. The pilot hole 105 provided in the steel plate 106 in FIG. 2 is for positioning reference of the steel plate 106 with respect to the press machine die. And the steel plate 106 is sequentially sent in a press according to the pitch between the pilot holes 105, and is sequentially processed.

  Next, at the position indicated by the arrow C, the portions where the thin portions 3b are formed and the portions where the thin portions 4b are formed are alternately alternately pressed, and the portions indicated by hatching in the drawing are press-punched, respectively. 2 magnetic plate members 3 and 4 are formed. Then, the first and second magnetic plate members 3 and 4 are sequentially laminated in a press die, and at the same time, punching and caulking are performed to form an integrated stator core 6 as shown in FIG. Next, after the winding 5 is applied to the core pieces 3a and 4a of the laminated first and second magnetic plates 3 and 4 as shown in FIG. 4, the thin portions 3b and 4b are bent. Thus, the annular stator core 6 is formed. Then, both end portions of the stator core 6 are brought into contact with each other and welded to form the stator 7 of the rotating electrical machine.

  As described above, according to the present embodiment, the magnetic plate material 3 includes the stator core 6 in which a plurality of magnetic plate materials 3 and 4 in which a plurality of core pieces 3a and 4a are connected via the thin portions 3b and 4b are stacked. In the stator 7 of the rotating electrical machine in which the stator core 6 is formed into an annular shape by bending the thin-walled portions 3b and 4b, and both ends of the stator core 6 are joined by welding, insulating coatings are formed on the welded portions on the front and back surfaces of the magnetic plates 3 and 4 Since the insulating coating was formed on the magnetic plate members 3 and 4 other than the welded portions on the front and back surfaces, the generation of bubbles due to impurities in the insulating coating during welding was suppressed, and the welding strength could be improved. .

  Moreover, the ratio of the cross-sectional area of the magnetic plate materials 3 and 4 which are magnetic flux paths can be increased, and the performance of the rotating electrical machine can be improved. In addition, since the material for the insulating coating can be reduced, it is economical. In particular, when the insulating material is composed of an organic material, the amount of the organic substance used as a global environmental load can be reduced.

Embodiment 2. FIG.
7 is a plan view showing a configuration of a stator of a rotating electrical machine according to Embodiment 2 of the present invention, FIG. 8 is a plan view showing a stator core in which magnetic plate members according to this embodiment are laminated, and FIG. 9 is a coil on the stator core of FIG. It is a top view which shows the state which wound.

  As shown in FIG. 8, the magnetic plate member 10 is formed by connecting a plurality of core pieces 11 via thin portions 12. A plurality of magnetic plate members 10 are laminated and fixed to each other by caulking or the like, thereby forming a stator core 15. And as shown in FIG. 9, the coil | winding 13 is wound by each core piece 11 of the stator core 15 which laminated | stacked the magnetic board | plate material 10. As shown in FIG.

  As shown in FIG. 7, the stator core 15 is formed in an annular shape by bending the thin portions 12 of the laminated magnetic plates 10. Both end portions of each magnetic plate 10 are brought into contact with each other at the contact portion 100 and joined by welding.

  In the present embodiment, as shown in FIG. 7, a non-insulating coating portion 101 on which no insulating coating is formed is formed in the vicinity of the contact portion 100 on the front and back surfaces of each magnetic plate member 10, that is, in the encircled dotted line portion of FIG. Form. An insulating coating is formed on portions other than the vicinity of the contact portion 100 of each magnetic plate member 10, that is, on the portion other than the non-insulating coating portion 101 indicated by a dotted line in FIG.

  The method for manufacturing the stator of the rotating electrical machine according to the second embodiment configured as described above is the same as the method described in the first embodiment, and a description thereof will be omitted.

  As described above, according to the present embodiment, the stator core 15 in which a plurality of magnetic plate members 10 in which a plurality of core pieces 11 are connected via the thin portion 12 is laminated is provided, and the thin portion 12 of each magnetic plate member 10 is provided. In the stator 16 of the rotating electrical machine in which the stator core 15 is bent to have an annular shape and both end portions of the stator core 15 are joined by welding, an insulating coating is not formed on the welded portions on the front and back surfaces of each magnetic plate member 10. Since the insulating coating is formed in areas other than the welded portions on the front and back surfaces, generation of bubbles due to impurities in the insulating coating is suppressed during welding, and the welding strength can be improved.

  Moreover, the ratio of the cross-sectional area of the magnetic plate 10 that is a path of magnetic flux can be increased, and the performance of the rotating electrical machine can be improved. Further, since the material for the insulating coating can be reduced, it is economical, and particularly when the insulating material is composed of an organic material, the amount of the organic substance used as a burden on the global environment can be reduced.

Embodiment 3 FIG.
In the third embodiment, the case where the stator manufactured according to the above embodiment is used in a rotating electric machine without being fixed to the stator frame will be described.

  FIG. 10 is a structural sectional view showing an example in which the stator of the present invention is attached to an in-vehicle generator. In FIG. 10, a rotating electrical machine 30 includes a case composed of a front bracket 31 and a rear bracket 32, a shaft 34 rotatably attached to the case via a bearing 33, and a field magnet fixed to the shaft 34. A rotor 36 having a winding 35; a stator 38 fixed to the case so as to surround the rotor 36 and having a winding 37; and a pulley 39 fixed to the front end of the shaft 34; The brush holder 40 is attached to the rear bracket 32 so as to be positioned on the rear side outer periphery of the shaft 34 and the pair of slip rings (not shown) attached to the rear side of the shaft 34 so as to be in sliding contact. A pair of brushes 41 disposed therein is provided. The rotating electrical machine 30 is connected to a rotating shaft of an engine (not shown) via a pulley 39 and a belt (not shown).

  The stator 38 has the structure described in the above embodiment, and includes a stator core obtained by stacking a plurality of magnetic plate materials in which a plurality of core pieces are connected via thin portions, and bends the thin portions of each magnetic plate material. The stator core is formed into an annular shape, and both end portions of the stator core are joined by welding. An insulating coating is not formed on the welded portion of each magnetic plate member, and an insulating coating is formed on the portions other than the welded portion of each magnetic plate member.

  Further, the stator 38 sandwiches both sides in the axial direction between the front bracket 31 and the rear bracket 32. And the stator 38 is being fixed to the said bracket by stopping the said brackets 31 and 32 with the volt | bolt 42. FIG. The brackets 33 and 34 are fixed to an engine (not shown) with bolts or the like through the flange portion 43.

  Since the stator frame of the rotating electric machine having the above structure is not mounted with a stator frame and is directly attached to the brackets 31 and 32, the reaction force of the torque that rotates the rotor 36 is directly applied to the stator 38 as an external force. Is done. A load is applied to the welded portion of the stator 38 in accordance with the torque from the outside. However, since an insulating coating is not formed on the welded portion of each magnetic plate material constituting the stator 38, and an insulating coating is formed on a portion other than the welded portion of each magnetic plate material, bubbles due to impurities in the insulating coating during welding are formed. Is suppressed, and the welding strength is improved. The welded portion has a sufficient strength against the external torque.

Embodiment 4 FIG.
FIG. 11 explains Embodiment 4 of the present invention and is a schematic diagram showing an operation of forming an insulating film on a steel plate. As shown in FIG. 11, the insulating coating 141 is attached on the steel plate 106 by the application roller 142. Forming a non-insulating coating part having no insulating coating in part can be realized by not applying a part of the steel plate 106. That is, in the case of FIG. 2 described above, the application of the coating roller 142 may be interrupted at the location of the line-shaped non-insulating coating portion 107 with respect to the steel plate 106, and in the case of FIG. On the other hand, the application by the application roller 142 may be interrupted only at the location of the non-insulating film portion 108. Further, after punching out a magnetic plate material in which a plurality of core pieces are connected via a thin portion from the steel plate 106, the insulating coating 141 may be attached to the magnetic plate material by the application roller 142, respectively. The insulating coating may be applied only to one surface of the steel plate 106 or the magnetic plate, that is, one surface of the steel plate or the magnetic plate.

  FIG. 12 is a cross-sectional view of a part of a stator core manufactured by laminating magnetic plates formed by applying an insulating coating. In the figure, the insulating coating 141 is not formed in the vicinity of the contact portion 100 on the surface of each magnetic plate 10, that is, in the non-insulating coating portion 101. An insulating coating 141 is formed on portions other than the portion 101.

  As described above, according to the present embodiment, by applying an insulating film to a steel plate or magnetic plate material by coating, a portion where the insulating film is adhered and a portion where the insulating film is not adhered can be easily separated and formed. Can do.

  In addition, when there are insulating coatings on both surfaces of the steel plate, the thickness of the insulating coating is doubled when laminated, and the ratio of the cross-sectional area of the magnetic plate effective as a magnetic path is reduced. However, according to the coating method of the present embodiment, since the insulating coating can be attached to only one side of the steel plate, that is, one side of the side where the steel plates are laminated, the ratio of the cross-sectional area of the magnetic plate material when laminated Can be increased.

  Moreover, you may apply | coat an insulating film only to the part used as a core instead of covering the whole surface in a steel plate. In this case, the amount of insulating coating to be used can be reduced to the minimum necessary, which is economical, and the amount of material used is small, leading to effective utilization of resources.

  Further, by installing the coating device in the press machine, it is possible to reduce the deviation between the position where the magnetic plate material is punched and the position where the insulating coating is applied. Moreover, the amount of organic substances used can be further reduced, and the economic effect and the effect of effective use of resources can be further obtained.

It is a top view which shows the structure of the stator of the rotary electric machine by Embodiment 1 of this invention. It is a figure which shows the process of forming the magnetic board material of Embodiment 1 by press punching. It is a top view which shows the state by which the magnetic board | plate material of Embodiment 1 was laminated | stacked. FIG. 3 is a plan view showing a state where a winding is applied to the magnetic plate material of the first embodiment. FIG. 3 is a cross-sectional view showing a configuration of a thin connecting portion of the magnetic plate material of the first embodiment. It is a figure which shows the process of forming the magnetic board material of Embodiment 1 by press punching. It is a top view which shows the structure of the stator of the rotary electric machine by Embodiment 2 of this invention. It is a top view which shows the stator core which laminated | stacked the magnetic board material by Embodiment 2. FIG. 6 is a plan view showing a state where a coil is wound around a stator core according to Embodiment 2. FIG. It is structural sectional drawing which shows the example which attached the stator of this invention to the vehicle-mounted generator. It is a schematic diagram which shows the operation | movement which forms an insulating film in the steel plate by Embodiment 4 of this invention. FIG. 6 is a partial cross-sectional view of a stator core manufactured by stacking magnetic plate materials according to a fourth embodiment.

3 first magnetic plate material, 4 second magnetic plate material, 3a, 4a core piece,
3b, 4b Thin portion, 5 windings, 6 stator core, 7 stator, 10 magnetic plate,
11 Core piece, 12 Thin part, 13 Winding, 15 Stator core, 16 Stator,
30 rotating electrical machine, 31, 32 bracket, 34 shaft, 36 rotor,
38 Stator, 100 Contact portion, 101 Non-insulating coating portion, 106 Steel plate,
141 Insulating film, 142 Application roller.

Claims (1)

A step of sequentially punching out a plurality of magnetic plate materials in a shape in which a plurality of core pieces are linearly connected via a thin portion from the steel plate in the longitudinal direction of the steel plate,
A step of laminating a plurality of the magnetic plate materials to form a stator core;
A method for manufacturing a stator of a rotating electrical machine comprising a step of bending a thin portion of the magnetic plate material to make the stator core annular and joining both end portions of the stator core by welding,
The steel plate prepared in the punching step has a line-shaped non-insulating coating portion extending in the longitudinal direction of the steel plate at a position corresponding to each end of the plurality of magnetic plate materials to be punched, and the non-insulating coating portion A method for manufacturing a stator of a rotating electrical machine, wherein an insulating film is formed except for the above.

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