JP5284847B2 - Method for manufacturing stator or rotor for electric motor - Google Patents

Description

The present invention relates to the production how the motor stator or rotor with a coil in the slot.

  In general, a stator for an electric motor having a coil in a slot is provided with an insulating member such as a resin insulator and an insulating paper formed by combining paper and a resin material in the slot, and the coil and the core are formed by the insulating member. Is insulated. In addition, there is known a stator for an electric motor including a coil in a slot, which includes a coil coated with an insulating varnish as a whole (see, for example, Patent Document 1).

  In order to prevent the coil from moving in the slot and causing an insulation failure, it is conceivable to integrate the coil with the insulating member with an insulating varnish in the motor stator in which the insulating member is provided in the slot.

  However, the stator for an electric motor including a coil integrated with an insulating member by an insulating varnish has a low coupling force between the insulating varnish and the insulating member because the insulating varnish and the insulating member are made of different materials. There is an inconvenience that the fixing to the surface becomes insufficient. In addition, since the insulating member and the slot are separate, there is a disadvantage that the coil cannot be prevented from moving in the slot.

  Furthermore, since the insulating member and the slot are separate and there is a gap between the insulating member and the slot, there is a disadvantage that Joule heat generated in the coil is not easily radiated to the stator for the motor.

  In addition, a motor rotor having a coil in the slot has the same disadvantages as the motor stator.

JP 2004-194398 A

The present invention is to solve such an inconvenience, integrated coils in the slot, the coil it is possible to prevent the movement in the slot, to provide a manufacturing how the motor stator or rotor with a high heat dissipation For the purpose.

In order to achieve such an object, the present invention provides a method for manufacturing a stator or rotor for an electric motor having a coil in a slot. A step of forming, a step of coating the insulating coating layer with a second resin material, a step of housing the coil in the slot covered with the insulating coating layer and the second resin material, and Heat-treating the accommodated slot to form a resin layer on the insulating coating layer, and integrating the coil into the slot via the insulating coating layer and the resin layer. Features.
In the manufacturing method of the present invention, first, the wall surface of the slot is coated with the first resin material, and then heat treatment is performed to form the insulating coating layer. Next, the insulating coating layer is covered with a second resin material. Next, a coil is accommodated in the slot covered with the insulating coating layer and the second resin material.
Next, by heat-treating the slot in which the coil is accommodated, the second resin material adheres to the periphery of the coil and penetrates into the gap of the coil to be thermally cured. As a result, a resin layer made of the second resin material can be formed on the insulating coating layer, and the coil can be integrated into the slot via the insulating coating layer and the resin layer.

As described above, according to the manufacturing method of the present invention, in the stator or rotor for an electric motor including a coil in the slot, the insulating coating layer made of the first resin material that covers the wall surface of the slot, and the insulating coating layer on the insulating coating layer It is possible to obtain a stator or rotor for an electric motor that includes the provided resin layer made of the second resin material, and the insulating coating layer and a coil integrated with the slot via the resin layer .

In the motor stator or rotor , an insulating coating layer is fixed to the wall surface of the slot, and a resin layer is formed on the insulating coating layer. At this time, since the insulating coating layer and the resin layer are both made of a resin material and have excellent affinity, the insulating coating layer and the resin layer are firmly fixed and integrated with each other.

The coil, as well is coated with a second resin material, the so are integrated into the slot through the insulating coating layer and the resin layer, to prevent the coil moves within the slot Can do.

Further, in the stator or rotor for an electric motor, the insulating coating layer made of the first resin material covers the wall surface of the slot and is in close contact with the wall surface, so that good thermal conductivity can be obtained. Heat dissipation can be obtained.

In the production method of the present invention, the first resin material may be a thermoplastic resin, but is preferably a thermosetting resin because of its excellent adhesion to a slot that is a metal. . Further, when a thermosetting resin is used as the first resin material, melting and deterioration of the insulating coating layer are suppressed even when the motor stator or rotor is at a high temperature. Adhesion between the slots can be maintained.

In the manufacturing method of the present invention, the second resin material may be a resin different from the first resin material, but is preferably the same resin as the first resin material. When the second resin material is the same resin as the first resin material, the insulating coating layer and the resin layer are more firmly adhered to each other, and the coil is reliably prevented from moving in the slot. be able to.

Moreover, in the manufacturing method of this invention, it is preferable that the said resin material contains the additive provided with heat conductivity higher than this resin material. According to the stator or rotor for an electric motor manufactured in this way, the thermal conductivity between the insulating coating layer made of the first resin material and the resin layer made of the second resin material can be improved. High heat dissipation can be obtained.

In the method for manufacturing a stator or rotor for an electric motor according to the present invention, it is preferable that the heat treatment is performed in a state where the coil is pressed against a wall surface of the slot. By doing in this way, a coil can be more firmly fixed to a slot.

Explanatory sectional drawing which shows the whole stator for electric motors. Explanatory sectional drawing which expands and shows the principal part of the stator for electric motors of 1st Embodiment. Explanatory sectional drawing which shows the initial state of the stator for electric motors shown in FIG. Process drawing which shows the 1st process of the manufacturing method of the stator for electric motors shown in FIG. Process drawing which shows the 2nd process of the manufacturing method of the stator for electric motors shown in FIG. Explanatory sectional drawing which expands and shows the principal part of the stator for electric motors of 2nd Embodiment. Explanatory sectional drawing which shows the initial state of the stator for electric motors shown in FIG. Process drawing which shows the 1st process of the manufacturing method of the stator for electric motors shown in FIG. Process drawing which shows the 2nd process of the manufacturing method of the stator for electric motors shown in FIG. Process drawing which shows the 3rd process of the manufacturing method of the stator for electric motors shown in FIG. Process drawing which shows the 4th process of the manufacturing method of the stator for electric motors shown in FIG.

  Next, embodiments of the present invention will be described in more detail with reference to the accompanying drawings. First, the stator 1 for an electric motor will be described with reference to FIG. The stator 1 for an electric motor is an annular body made of laminated electromagnetic steel sheets, and includes a plurality of slots 2 each having a bowl-shaped recess on the inner peripheral surface, and a coil (not shown) in the slot 2. The coil is made of a conductive wire covered with an insulating film and is accommodated in the slot 2.

  An annular rotor 3 is arranged on the inner peripheral side of the motor stator 1 with a predetermined distance from the inner peripheral surface of the motor stator 1. An annular permanent magnet 4 is disposed between the inner peripheral surface of the motor stator 1 and the outer peripheral surface of the rotor 3.

  In addition, although the stator 1 for motors is provided with the slot 2 on the inner peripheral surface of the annular body, the slot 2 may be provided on the outer peripheral surface instead of the inner peripheral surface. In that case, the annular rotor 3 is arranged on the outer peripheral side of the electric motor stator 1 with a predetermined distance from the outer peripheral surface of the electric motor stator 1, and the annular permanent magnet 4 is connected to the electric motor stator 1. Arranged between the outer peripheral surface and the inner peripheral surface of the rotor 3.

  Next, the motor stator 11 according to the first embodiment will be described with reference to FIG. FIG. 2 is an enlarged view of a portion of the motor stator 11 corresponding to part A of the motor stator 1 shown in FIG. The motor stator 11 of the first embodiment has the same configuration as that of the motor stator 1 shown in FIG. 1 except that it includes a slot 12 instead of the slot 2 and a coil 13 instead of a coil (not shown). .

  In the motor stator 11 shown in FIG. 2, the slot 12 has a wall surface covered with an insulating coating layer 14 made of a resin material. The coil 13 is covered with the resin material and integrated with the slot 12 via an insulating coating layer 14. Therefore, according to the motor stator 11 of the first embodiment, the coil 13 can be prevented from moving in the slot 12.

  Further, in the motor stator 11, since the insulating coating layer 14 made of a resin material covers the wall surface of the slot 12 and is in close contact with the wall surface, good thermal conductivity can be obtained. Therefore, the motor stator 11 can obtain high heat dissipation.

  As said resin material which comprises the insulation coating layer 14, thermoplastic resins, such as a polyamide resin, a polyester resin, and a polyphenylene sulfide resin, can be mentioned. However, the resin material is preferably a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, a polyimide resin, or a phenol resin because it has excellent adhesion to the metal slot 12. Further, when a thermosetting resin is used as the resin material, melting and deterioration of the insulating coating layer 14 are suppressed even when the stator 11 for an electric motor is at a high temperature. The adhesion between can be maintained.

  Moreover, it is preferable that the said resin material which comprises the insulating coating layer 14 contains the additive provided with heat conductivity higher than this resin material. According to the motor stator 11 having the above configuration, the thermal conductivity of the insulating coating layer 14 can be improved, and higher heat dissipation can be obtained. Examples of the additive include calcium carbonate, silicon oxide, aluminum oxide, talc, mica, silicon nitride, silicon carbide, and carbon nanotube.

  The stator 11 for electric motors of 1st Embodiment shown in FIG. 2 can be manufactured as follows. First, as shown in FIG. 4, the wall surface of the slot 12 of the stator core 11a shown in FIG. 3 is coated with a resin material to form a resin coating film 14a having a thickness in the range of 10 to 1000 μm. The resin material is, for example, an epoxy resin, and contains aluminum oxide as an additive having higher thermal conductivity than the epoxy resin in a range of 80% by mass or less.

  Next, as shown in FIG. 5, a coil 13 made of a conductive wire coated with the insulating coating is inserted and accommodated in the slot 12 in which the resin coating 14a is formed.

  Next, in a state where the coil 13 is pressed against the wall surface of the slot 12, the slot 12 in which the coil 13 is accommodated is heat-treated at a temperature in the range of 50 to 200 ° C. for 10 to 120 minutes. By the heat treatment, the resin material melted from the resin coating film 14a adheres to the periphery of the coil 13 and penetrates into the gaps of the coil 13, and then the resin material is cured.

  As a result, as shown in FIG. 2, an insulating coating layer 14 that covers the wall surface of the slot 12 is formed, and the coil 13 is integrated with the slot 12 via the insulating coating layer 14. It is possible to manufacture the stator 11 for an electric motor fixed to the motor.

  The heat treatment may not be performed in a state where the coil 13 is pressed against the wall surface of the slot 12, but the coil 13 is more firmly fixed to the slot 12 by performing the heat treatment while the coil 13 is pressed against the wall surface of the slot 12. be able to.

  Next, with reference to FIG. 6, the stator 21 for electric motors of 2nd Embodiment is demonstrated. FIG. 6 is an enlarged view of a portion of the motor stator 21 corresponding to part A of the motor stator 1 shown in FIG. The motor stator 21 of the second embodiment has the same configuration as the motor stator 1 shown in FIG. 1 except that it includes a slot 22 instead of the slot 2 and a coil 23 instead of a coil (not shown). .

  In the motor stator 21 shown in FIG. 6, the slot 22 has a wall surface covered with an insulating coating layer 24 made of a first resin material. The insulating coating layer 24 is fixed to the wall surface of the slot 22.

  A resin layer 25 made of a second resin material is provided on the insulating coating layer 24. At this time, since the insulating coating layer 24 and the resin layer 25 are both made of a resin material and have excellent affinity, the insulating coating layer 24 and the resin layer 25 are firmly fixed and integrated with each other.

  The coil 23 is covered with a second resin material, and is integrated with the slot 22 via an insulating coating layer 24 and a resin layer 25. Therefore, according to the motor stator 21 of the second embodiment, the coil 23 can be prevented from moving in the slot 22.

  Further, in the motor stator 21, since the insulating coating layer 24 made of the first resin material covers the wall surface of the slot 22 and is in close contact with the wall surface, good thermal conductivity can be obtained. Accordingly, the motor stator 21 can obtain high heat dissipation.

  Examples of the first resin material constituting the insulating coating layer 24 include thermoplastic resins such as polyamide resin, polyester resin, and polyphenylene sulfide resin. However, the first resin material is preferably a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, a polyimide resin, or a phenol resin because it has excellent adhesion to the metal slot 22. Further, when a thermosetting resin is used as the first resin material, melting and deterioration of the insulating coating layer 24 are suppressed even when the motor stator 21 is at a high temperature. Adhesion between the two can be maintained.

  Furthermore, it is preferable that not only the first resin material but also the second resin material is the thermosetting resin. When a thermosetting resin is used as the second resin material, melting and deterioration of the resin layer 25 are suppressed even when the motor stator 21 is at a high temperature. Can be maintained.

  Moreover, it is preferable that the 1st resin material which comprises the insulating coating layer 24, and the 2nd resin material which comprises the resin layer 25 contain the additive provided with heat conductivity higher than this resin material. According to the motor stator 21 having the above configuration, the thermal conductivity of the insulating coating layer 24 and the resin layer 25 can be improved, and higher heat dissipation can be obtained. Examples of the additive include calcium carbonate, silicon oxide, aluminum oxide, talc, mica, silicon nitride, silicon carbide, and carbon nanotube.

  In the motor stator 21, the second resin material may be a resin different from the first resin material, but is preferably the same resin as the first resin material. When the second resin material is the same resin as the first resin material, the insulating coating layer 24 and the resin layer 25 are more firmly adhered to each other, and it is ensured that the coil 23 moves in the slot 22. Can be prevented.

  The stator 21 for electric motors of 2nd Embodiment shown in FIG. 6 can be manufactured as follows. First, as shown in FIG. 8, the wall surface of the slot 22 of the stator core 21a shown in FIG. 7 is covered with a first resin material to form a first resin coating film 24a having a thickness in the range of 5 to 500 μm. To do. The first resin material is, for example, a phenol resin, and contains silicon oxide as an additive having higher thermal conductivity than the phenol resin in a range of 80% by mass or less.

  Next, the slot 22 in which the first resin coating film 24a shown in FIG. 8 is formed is heat-treated at a temperature in the range of 80 to 250 ° C. for 10 to 120 minutes. As a result of the heat treatment, the first resin coating 24 a is cured to form an insulating coating layer 24 that covers the wall surface of the slot 22 as shown in FIG. 9, and the insulating coating layer 24 adheres to the wall surface of the slot 22. Is done.

  Next, as shown in FIG. 10, the insulating coating layer 24 covering the wall surface of the slot 22 is coated with a second resin material, and a second resin coating film 25a having a thickness in the range of 5 to 500 μm is formed. Form. The second resin material is, for example, a phenol resin, and contains silicon oxide as an additive having higher thermal conductivity than the phenol resin in a range of 80% by mass or less.

  Next, as shown in FIG. 11, a coil 23 made of a conductive wire coated with the insulating coating is inserted and accommodated in the slot 22 in which the edge coating layer 24 and the second resin coating film 25a are formed.

  Next, in a state where the coil 23 is pressed against the wall surface of the slot 22, the slot 22 in which the coil 23 is accommodated is heat-treated at a temperature in the range of 50 to 200 ° C. for 10 to 120 minutes. By the heat treatment, the second resin material melted from the second resin coating film 25a adheres to the periphery of the coil 23 and penetrates into the gaps of the coil 23, and then the second resin material is cured.

  As a result, as shown in FIG. 6, a resin layer 25 is formed on the insulating coating layer 24, and the coil 23 is integrated with the slot 22 via the insulating coating layer 24 and the resin layer 25. An electric motor stator 21 having 23 fixed to the slot 22 can be manufactured.

  The heat treatment does not have to be performed in a state where the coil 23 is pressed against the wall surface of the slot 22, but the coil 23 is more firmly fixed to the slot 22 by being performed while the coil 23 is pressed against the wall surface of the slot 22. be able to.

  In addition, in the manufacturing method of the stator 21 for an electric motor according to the second embodiment, the slot 22 in which the first resin coating film 24a is formed is heat-treated to cure the first resin coating film 24a. The first resin coating film 24a may be preheated to be in a semi-cured state.

  In the present embodiment, the motor stators 11 and 21 including the coils 13 and 23 in the slots 12 and 22 and the manufacturing method thereof are described, but the same applies to the motor rotor including the coils in the slots and the manufacturing method thereof. This method is applicable.

  Next, examples and comparative examples of the present invention are shown.

  In this embodiment, first, the wall surface of the slot 12 of the stator core 11a made of an annular body made of laminated electromagnetic steel sheets is coated with an epoxy resin which is a thermosetting resin as a resin material, and a resin coating film having a thickness of 300 μm. 14a was formed.

  Next, a coil 13 made of a conductive wire covered with an insulating coating and having a diameter of 0.5 mm was inserted and accommodated in the slot 12 in which the resin coating film 14a was formed.

  Next, the slot 12 in which the coil 13 was accommodated was heat-treated at a temperature of 180 ° C. for 1 hour. By the heat treatment, the resin material melted from the resin coating film 14a adhered to the periphery of the coil 13 and penetrated into the gaps of the coil 13, and then the resin material was cured. As a result, the insulating coating layer 14 that covers the wall surface of the slot 12 is formed, the coil 13 is integrated with the slot 12 through the insulating coating layer 14, and the stator for the motor is fixed to the slot 12. 11 was obtained.

Next, a vibration durability test was performed on the motor stator 11 obtained in this example as follows. The vibration durability test was performed under the conditions of a frequency of 133 Hz, a vibration acceleration of 90 m / s ² , a vibration time of 4 hours in the vertical direction, 2 hours in the horizontal direction, and 2 hours in the front-rear direction.

  Next, the presence or absence of a crack was visually observed with respect to the stator 11 for electric motors. In the motor stator 11 of this example, no cracks were observed.

  Next, Joule heat was generated from the coil 13 by applying a current of 10 A to the coil 13 for 1 hour with respect to the motor stator 11 obtained in this example. A heat dissipation test was performed by measuring the surface temperature of the stator 11 for an electric motor. The surface temperature of the stator 11 for an electric motor of this example was 115 ° C.

  In this embodiment, first, the wall surface of the slot 22 of the stator core 21a made of an annular body made of laminated electromagnetic steel sheets is coated with an epoxy resin, which is a thermosetting resin as the first resin material, and has a thickness of 100 μm. A first resin coating film 24a was formed.

  Next, the slot 22 in which the first resin coating film 24a was formed was heat-treated at a temperature of 180 ° C. for 1 hour. By the heat treatment, the first resin coating film 24 a was cured to form an insulating coating layer 24 that covers the wall surface of the slot 22, and the insulating coating layer 24 was securely fixed to the wall surface of the slot 22.

  Next, the insulating coating layer 24 covering the wall surface of the slot 22 is coated with the same epoxy resin as the first resin material as the second resin material to form a second resin coating film 25a having a thickness of 300 μm. did.

  Next, a coil 23 made of a conductive wire covered with an insulating coating and having a diameter of 0.5 mm was inserted and accommodated in the slot 22 in which the insulating coating layer 24 and the second resin coating film 25a were formed.

  Next, the slot 22 in which the coil 23 was accommodated was heat-treated at a temperature of 180 ° C. for 1 hour. By the heat treatment, the second resin material melted from the second resin coating film 25a adhered to the periphery of the coil 23 and penetrated into the gaps of the coil 23, and then the second resin material was cured. As a result, a resin layer 25 is formed on the insulating coating layer 24, and the coil 23 is integrated with the slot 22 via the insulating coating layer 24 and the resin layer 25, and the coil 23 is fixed to the slot 22. An electric motor stator 21 was obtained.

  Next, a vibration durability test was performed on the electric motor stator 21 obtained in this example in the same manner as in Example 1. In the motor stator 21 of this example, no cracks were observed.

  Next, a heat dissipation test was performed on the electric motor stator 21 obtained in this example in exactly the same manner as in Example 1. The surface temperature of the stator 21 for an electric motor of this example was 118 ° C.

  In this example, the insulating coating layer 24 and the second resin coating film 25a were formed on the wall surface of the slot 22 of the stator core 21a made of an annular body made of laminated electromagnetic steel sheets in exactly the same manner as in Example 2.

  Next, the slot 22 in which the insulating coating layer 24 and the second resin coating film 25a were formed was heat-treated at a temperature of 120 ° C. for 10 minutes. By the heat treatment, the second resin coating film 25a was in a semi-cured state and further stabilized.

  Next, a coil 23 made of a conductive wire coated with an insulating coating and having a diameter of 0.5 mm was inserted and accommodated in the slot 22 where the insulating coating layer 24 and the second resin coating 25a in a semi-cured state were formed. .

  Next, the slot 22 in which the coil 23 was accommodated was heat-treated in exactly the same way as in Example 2. As described above, the resin layer 25 is formed on the insulating coating layer 24, the coil 23 is integrated with the slot 22 via the insulating coating layer 24 and the resin layer 25, and the coil 23 is fixed to the slot 22. An electric motor stator 21 was obtained.

  Next, a vibration durability test was performed on the electric motor stator 21 obtained in this example in the same manner as in Example 1. In the motor stator 21 of this example, no cracks were observed.

Next, a heat dissipation test was performed on the electric motor stator 21 obtained in this example in exactly the same manner as in Example 1. The surface temperature of the stator 21 for an electric motor of this example was 118 ° C.
[Comparative example]
In this comparative example, first, insulating paper formed by combining paper and a resin material was inserted into the wall surface of the slot of the stator for an electric motor made of an annular body made of laminated electromagnetic steel sheets.

  Next, a coil made of a conductive wire covered with an insulating coating and having a diameter of 0.5 mm was inserted and accommodated in the slot into which the insulating paper was inserted.

  Next, after heating for 1 hour at a temperature of 150 ° C. while dropping an unsaturated polyester varnish as an insulating varnish into the slot in which the coil is accommodated, the insulating varnish is further dropped and 1 at a temperature of 180 ° C. Heated for hours. By the heating, the insulating varnish was cured, and the stator for an electric motor in which the coil was integrated with the insulating paper with the insulating varnish was obtained.

  Next, a vibration durability test was performed on the motor stator obtained in this comparative example in exactly the same manner as in Example 1. In the motor stator of this comparative example, cracks were observed between the insulating paper and the insulating varnish.

  Next, a heat dissipation test was performed on the motor stator obtained in this comparative example in exactly the same manner as in Example 1. The surface temperature of the stator for an electric motor of this comparative example was 130 ° C.

  From the results of the vibration durability test, it is clear that the motor stator 11 of the first embodiment and the motor stator 21 of the second and third embodiments can prevent the coils 13 and 23 from moving in the slots 12 and 22. It is. On the other hand, it is apparent that the motor stator of the comparative example cannot prevent the coil from moving in the slot.

  From the results of the heat dissipation test, it is clear that the motor stator 11 of Example 1 and the motor stator 21 of Examples 2 and 3 have higher heat dissipation than the motor stator of the comparative example. It is.

  DESCRIPTION OF SYMBOLS 11 ... Stator or rotor for motors, 12 ... Slot, 13 ... Coil, 14 ... Insulation coating layer, 21 ... Stator or rotor for motors, 22 ... Slot, 23 ... Coil, 24 ... Insulation coating layer, 25 ... Resin layer.

Claims (5)

In a method for manufacturing a stator or rotor for an electric motor including a coil in a slot,
A step of coating the wall surface of the slot with the first resin material and then heat-treating to form an insulating coating layer;
Coating the insulating coating layer with a second resin material;
Accommodating the coil in the slot coated with the insulating coating layer and a second resin material;
Heat treating the slot containing the coil to form a resin layer on the insulating coating layer and integrating the coil into the slot via the insulating coating layer and the resin layer; A method for manufacturing a motor stator or rotor. The first resin material, manufacturing method of claim 1 an electric motor stator or rotor, wherein it is a thermosetting resin. The second resin material, according to claim 1 or claim 2 electric machine stator or rotor manufacturing method according to characterized in that the first resin material and same resin. The said resin material contains the additive provided with higher heat conductivity than this resin material, The manufacturing method of the stator or rotor for electric motors of any one of Claim 1 thru | or 3 characterized by the above-mentioned. The heat treatment method of the motor stator or rotor according to any one of claims 1 to 4, characterized in that said coil in a state of being pressed against the wall surface of the slot.

Images