JP5020676B2 - Stator part and method for manufacturing stator part - Google Patents

Description

The present invention is used as a part of a coil material wound around a stator magnetic pole of a rotating electric machine, and has a long conductor plate and an insulating sheet attached to the surface side of the stator component and its manufacture Regarding the method.

In a rotating electric machine composed of a stator and a rotor, for example, a stator of a synchronous motor, a conductor coil is wound around a slot formed between magnetic pole portions provided in a stator core. Since the inside of the portion in the radial direction is widened, there is a problem that winding is extremely difficult. Therefore, as shown in Patent Document 1, a long conductor plate pressed into a part of each winding is used, and insulation between layers (turns) is performed by an insulating sheet disposed between the long conductor plates. .
An outline of this state is shown in FIG. 5, and a coil (conductor) 63 is provided in a slot 62 formed between the magnetic pole portions 61 of the stator core 60. The coil 63 is formed by laminating a plurality of long conductor plates 64 that are U-shaped or linear with an insulating sheet 65 interposed therebetween. The long conductor plates 64 arranged on the outer side in the radial direction are wide, but the side surfaces of the respective long conductor plates 64 constituting the coil 63 on the side arranged close to the magnetic pole portion 61. Has a vertical surface shape, and the opposite side surface has a stepped shape. The width of the long conductor plate 64 gradually decreases inward in the radial direction.

JP-A-2005-160143

However, since each long conductor plate 64 is produced by press working, a punching burr 68 is generated on the cut end face 67 as it is. As shown in FIG. 6A, when the punching burr 68 is formed on the side to which the insulating sheet 65 is adhered, the layer is in contact with the upper long conductor plate 64 beyond the end of the insulating sheet 65 during lamination. There is a problem of causing a short circuit. Alternatively, as shown in FIG. 6B, when the punching burr 68 is formed on the side opposite to the side on which the insulating sheet 65 is adhered, the lower insulating sheet 65 is broken at the time of lamination, and the lower long There is a problem of causing an interlayer short circuit in contact with the conductor plate 64. For this reason, for example, a technique such as shaving has been proposed so that the punching burr 68 does not occur on the end surface of the long conductor plate 64. However, the insulation distance of the long conductor plate 64 is only the thickness of the insulation sheet 65, and the end is exposed. Therefore, the insulation distance between the layers is small, and an interlayer short circuit occurs due to adhesion of foreign matter or wrinkles. There was a problem that there might be.

The present invention has been made in view of such circumstances, and the punching burrs formed at both ends in the width direction of the long conductor plate do not break the insulating sheet, and the insulation distance in the case of lamination becomes long, resulting in an interlayer short circuit. An object of the present invention is to provide a stator part that is less likely to generate a crack and a manufacturing method thereof.

The stator component according to the first aspect of the present invention, which is used as a part of the coil material wound around the stator magnetic pole, is punched from a wide conductor plate having an insulating sheet attached to the surface side. resulting Te, a component stator having said insulating sheet is stuck on its surface elongated conductive plate,
Steps are formed at both end portions in the width direction orthogonal to the longitudinal direction on the back side of the long conductor plate, and both end portions in the width direction of the long conductor plate are thinned.

In the stator component according to the first aspect of the present invention, it is preferable that the long conductor plate is linear, and the back surfaces on both sides in the longitudinal direction of the long conductor plate are thinned. As a result, a gap is generated at both ends in the longitudinal direction of the stacked long conductor plates adjacent to each other, and a connecting plate connecting the long conductor plates can be inserted into the gap.

In the stator component according to the first aspect of the present invention, the width of the step formed on the long conductor plate is preferably in the range of 0.3 to 2 times the plate thickness of the long conductor plate. If it is less than this range, the distance between the insulation layers becomes shorter, and if this range is exceeded, the cross-sectional area of the long conductor plate decreases and the resistance increases.

Further, in the stator component according to the first invention, the thickness of the thin portion of the long conductor plate on which the step is formed ranges from 0.3 to 0.7 of the plate thickness of the long conductor plate. It is good to be in. Here, if the thin portion is less than 0.3 times the plate thickness, end processing (for example, shaving processing) becomes difficult, and if it exceeds 0.7 times, the insulation distance between layers becomes small.

And the manufacturing method of the components for stators concerning the 2nd invention is used as a part of coil material wound around a stator magnetic pole, and is a long conductor board and the insulating sheet stuck on the surface side A method for manufacturing a stator component made of a long conductive material comprising:
A first step of preparing a wide conductor plate having a length of the long conductive material, the back surface side of both sides being thinned to become a thin plate and the surface is attached with the insulating sheet;
A second step of performing a preliminary punching process on the wide conductor plate and cutting out the raw material of the long conductive material whose both ends are connected to the wide conductor plate;
A third step of forming a step on both sides in the width direction orthogonal to the longitudinal direction of the long conductor plate of the raw material to make it thin;
Performing a shaving process on both ends of the raw material on which the step is formed, and forming a width direction both ends of the insulating sheet and the long conductor plate; and
And a fifth step of separating the long conductive material from the wide conductor plate.

In the third step, the step of forming the step on both sides in the width direction of the long conductor plate to make it thin may use a stepped mold, or the plate-shaped mold is pressed against the end. You may stop in position.
Moreover, although it is preferable to insert a cutter from the side by which the insulating sheet is affixed for shaving, this invention is applied also when inserting a cutter from the opposite side.

The stator component and the manufacturing method thereof according to the present invention have the following effects.
(1) Steps are formed at both ends in the width direction on the back side of each long conductor plate, and both end portions in the width direction of the long conductor plate are thinned, so that an insulation distance between the stacked long conductor plates can be secured. A highly reliable rotating electrical machine can be obtained.
(2) There is no possibility of breaking the insulating sheet disposed between the layers by burrs generated at both ends in the width direction of the long conductor plate.
(3) Since a long conductor plate is used as the coil material wound around the stator magnetic pole, the filling density into the slot is increased, and the internal resistance of the coil material can be reduced to provide a high-performance rotating electric machine.
(4) From the above, it is possible to provide a rotating electrical machine that is more compact with the same output.

In particular, the method for manufacturing a stator component according to the present invention has the following effects.
(5) Since the raw material of the long conductive material is cut out by pre-cutting the prepared wide conductor plate, the stress of the long conductive plate is released, and the subsequent highly accurate step shape and planar shape are obtained. It can be secured.
(6) Since the shaving process is further performed after the both ends of the long conductor plate are stepped, the end surfaces of the long conductor plate can be aligned and the dimensional accuracy can be increased.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIGS. 1A and 1B are a side view and a front sectional view of a stator component according to an embodiment of the present invention, and FIGS. 2A and 2B are stator components. FIG. 3 is an explanatory view for explaining a method for manufacturing the stator component, and FIG. 4 is a partial plan view of a wide conductor plate for obtaining the stator component.

As shown in FIG. 1A, a stator component 10 according to an embodiment of the present invention includes a long conductor plate 11 made of a straight copper plate and an insulating sheet 12 attached to the surface thereof. Made of a long conductive material, and the back surfaces of both sides in the longitudinal direction of the long conductor plate 11 are uniformly thinned to have a thickness of 0.4 to 0.6 (preferably the thickness of the central portion of the long conductor plate 11). Is 0.5) times. As shown in FIG. 2A, the length a of the thinned portions 13 and 14 is 0.8 to 2.0 (more preferably 0.9 to the width of the maximum width stator component 10 to be laminated. 1.5) times.

As shown in FIG. 1B, thin portions 17 and 18 having steps 15 and 16 are formed on both sides in the width direction (that is, the short direction) on the back side of the long conductor plate 11. Yes. The thickness of the thin portions 17 and 18 is in the range of 0.3 to 0.7 (more preferably 0.4 to 0.6) times the thickness of the long conductor plate 11, and the width of the thin portions 17 and 18; That is, the width of the steps 15 and 16 is in the range of 0.3 to 2 times (more preferably, 0.8 to 1.2 times) the thickness of the long conductor plate 11.

The insulating sheet 12 adhered to the surface side of the long conductor plate 11 is a heat-resistant synthetic resin sheet, and for example, a polyimide sheet is preferably used, but the present invention is not limited to this. Alternatively, other synthetic resin sheets and thin sheets of ceramics (for example, mica) may be used. Although the thickness of this insulating sheet 12 changes with materials to be used, the voltage applied to a rotary electric machine, and a use, if it is the range of 0.05-1.5 mm, for example, is enough. When the insulating sheet 12 is a synthetic resin, a synthetic resin-based adhesive is used. When the insulating sheet is an inorganic material, the insulating sheet 12 is preferably bonded to the long conductor plate 11 using an inorganic-based adhesive. 2A and 2B, a long conductive material may be laminated and finally hardened with a resin such as epoxy.

FIGS. 2A and 2B show a stator component 10 having a predetermined width, which is laminated and wound around the stator magnetic poles 19 and 20. The stator parts 10 have the same length, but the width is narrowed in order from the bottom to the top, the narrower side is on the magnetic pole tip side, and the wider side is on the yoke side, Mounted on the stator poles. In this case, as shown in detail in FIG. 2B, a vertical surface is formed on the center side of the coil members 19 and 20, and stepped portions are formed on both outer sides. As a result, the insulating interval between the long conductor plates 11 adjacent to each other not only in the thickness of the insulating sheet 12 but also the widths of the steps 15 and 16 contribute to the insulating interval, thereby improving the insulation between the layers.

Since the thinned portions 13 and 14 are formed on the back surfaces on both sides of each long conductor plate 11, slits (gap) 21 and 22 are formed on both sides of the coil materials 19 and 20 in which these are laminated. A connecting member 23 having a connecting plate is inserted into each of the slits 21 and 22, and one connecting plate sequentially connects the long conductor plates 11 of different layers of the coil members 19 and 20. ing. As a result, the long conductor plates 11 and the connecting plates forming the coil members 19 and 20 and the connecting members 23 on both sides are connected in series, so that one coil is formed as a whole.

Next, an embodiment of a method for manufacturing the stator component 10 will be described with reference to FIGS.
As shown in FIG. 4, a wide conductor plate 25 made of a thin copper plate (thickness is 0.5 to 3 mm, for example) that is 1 to 3 cm longer than the entire length of each long conductor plate 10 is prepared. The back surfaces on both sides of the wide conductor plate 25 are previously reduced in thickness to about 0.4 to 0.6 times the thickness of the center. An insulating sheet 12 is attached to the entire surface of the wide conductor plate 25. FIG. 4 shows the back side of the wide conductor plate 25.

Then, as shown in FIG. 3, the stator part 10 is manufactured via the stations A to G. FIG. 4 shows the stations A to C.
At station A, pilot holes 26 and 27 are formed at both ends of the wide conductor plate 25 in the width direction. This is because the wide conductor plate 25 is intermittently conveyed into the mold apparatus at a predetermined pitch.

Next, a first preliminary punching process is performed at the station B with reference to the pilot holes 26 and 27 to form the first long holes 28 in the wide conductor plate 25. The length of the long hole 28 is made slightly longer (for example, about 2 mm) than the length of the long conductor plate 11. In this embodiment, as shown in FIG. 4, long holes 28 are formed sequentially. In this case, the interval between the adjacent long holes 28 is sufficiently longer than the long conductor plate 11 having the maximum width.

Next, a second preliminary punching process is performed at the station C with reference to the pilot holes 26 and 27 to form the second long holes 29. A raw material 30 of each long conductive material is formed by the second long hole 29 and the first long hole 28. In addition, the width | variety of the raw material 30 is 0.5-2 mm longer than the width | variety of the elongate conductor board 11 manufactured from it, for example.

At station D, steps 15 and 16 are formed at both ends of the raw material 30. The steps 15 and 16 may be formed with a stepped cutter from the back side, or a flat cutter may be pressed from the back side to a predetermined position. As a result, both ends of the raw material 30 are widened within a slight range. The processing for attaching the steps 15 and 16 is performed simultaneously on the left and right. This prevents the raw material 30 from escaping in one direction.

In stations E and F, a shaving process 31 for removing the protruding portion of the raw material 30 and making the cut surface vertical is sequentially performed. You may perform the shaving process of both ends simultaneously.
In the station G, by performing the side cut 32, the stator part 10 with the insulating sheet 12 adhered to the surface side of the long conductor plate 11 is removed from the wide conductor plate 25, and this is continuously repeated. The stator part 10 having a predetermined width is completed.

In the above-described embodiment, the linear stator component has been described. However, the present invention can be applied to a stator component bent in a U-shape.
Moreover, in the said embodiment, when each coil material (namely, stator component 10) is laminated | stacked, although the width differed in the lamination direction, this invention is applied also when it is set as the same width.

(A) and (B) are the side view and front sectional drawing of the stator components which concern on one embodiment of this invention. (A), (B) is the top view and sectional drawing of the coil material which used the components for the same stator. It is explanatory drawing which shows the manufacturing method of the components for the same stator. It is a fragmentary top view of the wide conductor board which obtains the components for the same stator. It is explanatory drawing of the components for a stator (winding) which concerns on a prior art example. (A), (B) is explanatory drawing of the problem of the components for stators concerning a prior art example, respectively.

10: parts for stator, 11: long conductor plate, 12: insulating sheet, 13, 14: thinned portion, 15, 16: step, 17, 18: thin portion, 19, 20: coil material, 21, 22 : Slit, 23: connecting material, 25: wide conductor plate, 26, 27: pilot hole, 28: first long hole, 29: second long hole, 30: raw material, 31: shaving, 32: side cut

Claims (5)

Used as part of the coil material wound around the stator magnetic pole, obtained by punching from a wide conductor plate with an insulating sheet attached to the surface side, and attached to the long conductor plate and its surface side and that the a stator parts having an insulating sheet,
A component for a stator, wherein steps are formed at both ends in the width direction orthogonal to the longitudinal direction on the back side of the long conductor plate, and both ends in the width direction of the long conductor plate are thinned. 2. The stator component according to claim 1, wherein the elongated conductor plate is linear, and the back surfaces on both sides in the longitudinal direction of the elongated conductor plate are thinned. . 3. The stator part according to claim 1, wherein the width of the step formed on the long conductor plate is in a range of 0.3 to 2 times the plate thickness of the long conductor plate. And stator parts. The stator part according to any one of claims 1 to 3, wherein a thickness of the thin portion of the long conductor plate on which the step is formed is 0.3 to 0.3 mm of a thickness of the long conductor plate. Stator part characterized by being in the range of 0.7. It is used as a part of a coil material wound around a stator magnetic pole, and is a method of manufacturing a component for a stator made of a long conductive material having a long conductor plate and an insulating sheet attached to the surface side thereof. There,
A first step of preparing a wide conductor plate having a length of the long conductive material, the back surface side of both sides being thinned to become a thin plate and the surface is attached with the insulating sheet;
A second step of performing a preliminary punching process on the wide conductor plate and cutting out the raw material of the long conductive material whose both ends are connected to the wide conductor plate;
A third step of forming a step on both sides in the width direction orthogonal to the longitudinal direction of the long conductor plate of the raw material to make it thin;
Performing a shaving process on both ends of the raw material on which the step is formed, and forming a width direction both ends of the insulating sheet and the long conductor plate; and
And a fifth step of separating the long conductive material from the wide conductor plate.

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