JP5901432B2 - Armature and armature manufacturing method - Google Patents

Description

  The present invention relates to an armature and a method for manufacturing an armature that can prevent a coil from dropping and disconnecting due to vibration based on external factors.

In recent years, various technological developments have been made for the purpose of improving the efficiency of rotating electrical machines.
One way to reduce the electrical loss of an electric motor is to increase the proportion of copper wire wound around the stator in the winding space (so-called space factor), thereby generating heat from copper (so-called copper loss). There is a way to suppress this.

In the so-called direct winding method in which the coil is directly wound around the core via the insulating member, the coil cannot be tightly wound around the core but swells and cannot be effectively wound around the winding possible region.
In particular, as the coil becomes thicker, this tendency becomes more prominent and becomes an impediment to improving the space factor.
In such a case, after the coil is once wound on another winding frame, the bulge portion of the coil is corrected from the outside and then inserted into the core.
By adopting such an assembly process, the space factor of the winding can be improved.

In recent years, as a further measure to improve the space factor, an increasing number of cases have been applied to edgewise coils that are formed by bending a short wire with a rectangular cross section inside the coil axis. It is coming.
Similarly, when the edgewise coil is employed, the stator is completed by an assembly method in which the edgewise coil is formed as a separate body and then inserted into the teeth. (For example, Patent Document 1)

In addition, these electric motors have recently been applied as automobile driving motors.
A motor used for driving an automobile is used in a severe environment, and it is assumed that excessive vibration is applied to the motor. Therefore, a motor with high vibration resistance is required.
In particular, there is a concern that the coil portion may drop off or break due to vibration. In response to such a concern, a configuration has been disclosed in which positioning is performed by bending a hook portion of a tooth tip after inserting a coil into the tooth. (For example, Patent Document 2)

JP 2010-136486 A JP 2010-93918 A

In the technique described in Patent Document 1, since there is no means for directly fixing the coil and the core, the insulator and the coil may drop from the core.
Then, although a coil is fixed with a varnish or a mold, the subject that assembly cost increased occurred.

Moreover, in the technique described in Patent Document 2, a configuration is adopted in which a collar is positioned by bending a hook portion provided at an inner front end of the tooth portion in the circumferential direction of the stator after inserting the coil.
As the second member having the flange, a thin steel plate is usually used in order to prevent an increase in iron loss.
The flange provided on the thin plate is initially a plate-like portion protruding in the radial direction of the stator, and it is necessary to perform a so-called edgewise bending process in which this is bent in the circumferential direction of the stator.

  When the aspect ratio between the thickness of the buttock and the width of the bent portion is large, the buttock tends to be deformed in the out-of-plane direction during the bending process. There was a problem that positioning could not be performed accurately.

In addition, in order to suppress the out-of-plane deformation of the collar part, there is a method of bending while guiding the collar part by providing an out-of-plane deformation regulating tool, but the collar parts are alternately arranged in a staggered manner with respect to the core stacking direction. In the case of the structure, there is a problem that the assembly cost increases because the tool becomes complicated.
Furthermore, if the width of the bent part is reduced to reduce the aspect ratio of the collar part, out-of-plane deformation in the collar part becomes difficult to occur, but the strength of the collar part itself is reduced, so the function of fixing the coil is fully demonstrated. There was a problem that it was not possible.

  The present invention has been made to solve such a problem, and an armature and an electric machine that can be easily fixed to a tooth after a coil body previously formed as a separate body is attached to a tooth of a split core. It aims at providing the manufacturing method of a child.

The armature according to this invention is
A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
Cutout portions are provided at both ends of the fixing member on the boundary line between the split core fixing portion and the coil body holding portion .
The armature according to the present invention is
A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
A plurality of the coil body holding parts are provided for the divided core fixing part.
The armature according to the present invention is
A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
At both ends of the fixing member on the boundary line between the split core fixing part and the coil body holding part, a notch is provided,
A plurality of the coil body holding parts are provided for the divided core fixing part .
In addition, the method of manufacturing the armature includes
A fixing member joining step in which the planar fixing member is joined to the axial end surface of the stator of the split iron core so that the coil body holding portion protrudes from the teeth portion to the inside of the stator;
A coil body mounting step of mounting the coil body on a tooth portion of the split core;
A fixing member bending step of bending the coil body holding portion of the fixing member substantially at a right angle to fix the coil body to the divided iron core.

The armature and the armature manufacturing method according to the present invention are:
Since it is comprised as mentioned above, even if it receives the vibration from the outside, a coil does not drop from the teeth part of a split iron core. Further, since the thin plate fixing member can be bent in the flatwise direction as the coil fixing structure, the bending process can be easily performed and the strength of the fixing member can be maintained.

It is a perspective view of the armature which concerns on Embodiment 1 of this invention. It is a front view which shows the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view of the coil body which concerns on Embodiment 1 of this invention. It is an exploded view of the coil body which concerns on Embodiment 1 of this invention. It is a perspective view of the coil which concerns on Embodiment 1 of this invention. It is a perspective view of the insulator which concerns on Embodiment 1 of this invention. It is a perspective view of the insulating sheet which concerns on Embodiment 1 of this invention. It is a figure which shows the example of the position of the overlapping part of the insulating sheet which concerns on Embodiment 1 of this invention. It is a perspective view of the split iron core 1 which concerns on Embodiment 1 of this invention. It is a top view of the fixing member which concerns on Embodiment 1 of this invention. It is a perspective view which shows the state which joined the fixing member to the split iron core 1 which concerns on Embodiment 1 of this invention. It is a figure which shows the process of attaching a coil body to the split iron core which attached the fixing member which concerns on Embodiment 1 of this invention. It is a top view which shows the other example of the fixing member which concerns on Embodiment 1 of this invention. It is sectional drawing which shows an example of the structure which fixes a fixing member to the split iron core which concerns on Embodiment 1 of this invention. It is a top view which shows the other example of the fixing member which concerns on Embodiment 1 of this invention. It is a perspective view of the armature which concerns on Embodiment 2 of this invention. It is a partially transparent perspective view of the coil body which concerns on Embodiment 2 of this invention.

Embodiment 1 FIG.
Hereinafter, an armature and a manufacturing method thereof according to Embodiment 1 of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of the armature 100.
In the present specification, an armature 100 is one in which a coil body 2 is attached to one divided core 1.

FIG. 2 is a front view of a stator 130 in which a plurality of armatures 100 are combined in a ring 3 and fitted into the frame 3.
The frame 3 has a fastening margin, and the plurality of armatures 100 are fixedly held by press-fitting or shrink-fitting the plurality of armatures 100 therein.
FIG. 3 is a perspective view of the coil body 2. This is a portion obtained by removing the split iron core 1 from the armature 100 shown in FIG.
FIG. 4 is an exploded view of the coil body 2.

  The armature 100 is composed of a coil 21 in which a conducting wire is previously formed into an annular shape, an insulator 22 attached inside the coil end portion of the coil 21, and an insulating sheet 23 covering the outer periphery of the coil 21 other than the coil end portion. The shaft portion of the tooth portion of the split iron core 1 is inserted on the inner peripheral side of the body 2.

Next, each member which comprises the coil body 2 is demonstrated in order.
FIG. 5 is a perspective view of the coil 21.
Hereinafter, both ends of the coil 21 in the axial direction of the stator 130, that is, the short side portion of the coil 21 shown in the drawing is referred to as a coil end portion 21 a.
Further, the portion of the long side of the coil shown in the figure that is housed in the stator slot is referred to as an in-slot housing portion 21b.

Both ends of the coil 21 are exposed to the outside as two terminal wires 21c and 21d.
The terminal wires 21c and 21d are three-phase connected after the armatures 100 are assembled in the state of the stator 130.
In the present embodiment, the terminal lines 21c and 21d protrude in the same direction, but may be arranged in opposite directions.
In that case, connections are made at both axial ends of the stator 130.
The coil 21 is made of a conductor whose surface is covered with an insulating film such as polyamideimide.
The coil 21 is preliminarily formed by winding a rectangular wire or a round wire having a rectangular conductor cross section around a winding frame or the like.

FIG. 6 is a perspective view of the insulator 22.
The insulator 22 is a member disposed between the coil 21 and the split iron core 1 and covers portions corresponding to both end portions in the axial direction of the stator of the tooth portion of the split iron core 1.
The insulator 22 includes a coil receiving portion 22a along the inner peripheral surface of the coil end portion 21a of the coil 21, an outer flange 22b disposed on the side surface on the yoke side of the split core 1 of the coil receiving portion 22a, and an outer flange 22b. It is comprised by the inner collar 22c arrange | positioned at the teeth front-end | tip part side of the coil receiving part 22a so that it may oppose.

In addition, a concave groove 22d is provided in the axial direction of the stator 130 on the inner peripheral side of the stator 130 of the inner flange 22c.
The outer rod 22b and the inner rod 22c restrict the coil end portion 21a from protruding outside or inside the stator 130 and insulate the coil 21 from the divided iron core 1.
The insulator 22 is molded using a heat-resistant thermoplastic resin or thermosetting resin.

FIG. 7 is a perspective view of the insulating sheet 23.
The insulating sheet 23 is a member that surrounds the inside of the slot accommodating portion 21 b of the coil 21 and electrically insulates between the coil 21 and the split iron core 1.
The teeth insulating part 23 a is a part sandwiched between the side surface of the tooth part 11 b and the inner peripheral surface of the coil 21.
The yoke insulating portion 23 b is a portion that covers the side surface of the coil 21 on the yoke side.
The tooth tip insulating portion 23 c is a portion that covers the tooth tip side of the coil 21.
The interphase insulating portion 23 d is a portion that covers the outermost outer peripheral surface of the coil 21 and ensures interphase insulation between adjacent coils when the plurality of armatures 100 are assembled as the stator 130.
As the insulating sheet 23, a material having heat resistance and insulating properties is used, and a sheet in which a plurality of sheets are stacked, for example, a sheet in which aramid paper-PPS-aramid paper is stacked is used.

Next, the assembly procedure of the coil body 2 will be described.
The case where an edgewise coil is used as the coil 21 will be described, but the same applies to a coil wound with a round wire.
First, the insulating sheet 23 is wound around the in-slot housing portion 21b of the coil 21 that has been wound in advance.
Two insulating sheets 23 having the same shape are used and wound around the in-slot housing portion 21b of the coil 21, respectively.
At that time, the insulation between the adjacent coils 21 is ensured by overlapping the interphase insulating portion 23 d of the insulating sheet 23 at the outermost peripheral portion of the coil 21.
FIG. 8 is a diagram illustrating another example of the overlapping portion of the insulating sheets.
The position where the insulating sheet 23 is overlapped may be on the yoke portion side of the split iron core 1 indicated by A in FIG.
When the insulating sheet 23 is overlapped at the portion A, a wider rectangular wire can be used for the coil than when overlapping between adjacent coils (correlation).
Thereby, the space factor of the coil 21 can be improved.

Next, the structure of the split iron core 1 will be described.
FIG. 9 is a perspective view of the split iron core 1.
The split iron core 1 includes a yoke portion 11a and a tooth portion 11b.
The split iron core 1 is configured by laminating thin steel plates.
The iron loss of the armature 100 can be suppressed by using a silicon steel plate as the thin steel plate.
In addition, the fixing between the stacked layers is a post-process that follows the step of punching out the core pieces with a press, and the core pieces that are stacked up and down by caulking dowels 11d, 11e, and 11f are fixed together.
The caulking shape is a round shape in FIG. 9, but a caulking shape having a V-shaped cross section may be adopted.
Although not shown in the drawings, there are other fixing methods such as a method of fixing the laminated layers by adhesion and a method of fixing by welding.

Next, a fixing member for fixing the divided core 1 and the coil body 2 and a method for using the fixing member will be described.
FIG. 10 is a plan view of the fixing member 4.
FIG. 11 is a view showing a state in which the fixing member 4 is joined to the divided iron core 1.
The fixing member 4 is a single steel plate composed of a split core fixing part 41 and a coil body holding part 42.
The split core fixing portion 41 has substantially the same shape as the core pieces constituting the split core 1.
The coil body holding portion 42 is provided so as to protrude from the tip end portion of the teeth of the split iron core fixing portion 41 toward the inside of the stator.
Further, notches 4k are provided at the base of the coil body holding portion 42, that is, at both ends of the boundary line with the divided core fixing portion 41.
When the coil body holding portion 42 is bent by the notch portion 4k, stress concentration occurs in the notch portion 4k, and the fixing member 4 is easily bent along a line connecting the two notch portions 4k.
The fixing member 4 is disposed on both end surfaces of the split iron core 1.

Further, the fixing member 4 is provided with crimping dowels 4d, 4e, and 4f at positions where they can be joined to the crimping dowels 11d, 11e, and 11f of the split iron core 1 shown in FIG.
The fixing member 4 is fixed to the split iron core 1 by caulking these crimping dowels to each other. (Fixing member joining process)
The material of the fixing member 4 may be the same as the material of the split iron core 1, for example, or SPCC may be used.
If the same material as the split core 1 is used, a step of punching the periphery of the coil body holding portion 42 of the fixing member 4 with a press die can be added, and the fixing member 4 can be manufactured at the same time as the split core 1 is manufactured inside the press. 1 can be manufactured and taken out integrally.
Thereby, the space factor of an iron core also improves and it contributes to a torque improvement.

FIG. 12 is a diagram illustrating a process of attaching the coil body 2 to the split iron core 1 to which the fixing member 4 is attached (coil body mounting process).
As shown in FIG. 12A, the tooth portion 11 b of the split iron core 1 is fitted from the tip side along the inner peripheral surface of the coil body 2.
At this time, the insulator 22 and the fixing member 4 are in contact with each other on a plane.
When the teeth portion 11b is completely fitted, the coil body holding portion 42 of the fixing member 4 is perpendicular to the outer circumferential side of the coil body 2 in the axial direction of the stator 130 as shown in FIG. It is bent and plastically deformed. (Fixing member bending process)

The coil body holding portion 42 is accommodated in the groove 22d of the outer wall of the inner flange 22c of the insulator 22 without any step as shown in FIG. 12 (c), and fixes the coil body 2 to the divided iron core 1.
As described above, the coil body holding portion 42 is preferably arranged so as not to be stepped on the outer peripheral surface of the insulator 22 and to protrude inside the stator 130.
Thereby, there is no restriction on the direction in which a rotor (not shown) disposed inside the stator 130 is assembled, and the rotating electrical machine can be assembled from both sides in the axial direction.

A step of fixing the fixing member 4 and the split core 1 may be provided separately from the manufacturing step of the split core 1, and the two members may be integrated later.
In this case, as a fixing method, adhesion, welding, or other methods are used.
FIG. 13 is a view showing a fixing member 44 which is another example of the fixing member 4.
The fixing member 44 is provided with a through long hole 44g.
FIG. 14 shows a structure for fixing the fixing member 44 to the split iron core 1.
A retaining slot 1g is provided on the end surface of the split iron core 1 corresponding to the position of the through slot 44g of the fixing member 44.
The two elongated holes are aligned, and the retaining pin 5 is press-fitted to fix the fixing member 44 to the divided iron core 1.
By adopting such a fixing method, SPCC which is softer and has better workability than a hard electromagnetic steel sheet containing silicon can be used as a material for the split iron core and the fixing member.
Thereby, the assembly property of the armature 100 is improved.

FIG. 15 is a view showing a fixing member 45 which is another example of the fixing member 4.
As shown in the figure, a configuration is adopted in which the coil body holding portion is divided into coil body holding portions 42a and 42b.
By making the coil body holding portion bifurcated, the coil body 2 can be pressed at a position offset from the center of the inner flange 22c of the insulator 22.
Thereby, the inclination of the coil body 2 with respect to the teeth part 11b can be made small.
Further, since the bending force per one of the coil body holding portions 42a and 42b can be reduced, the assembly of the armature 100 can be facilitated.

According to the armature 100 according to the first embodiment of the present invention, it is possible to prevent the coil body 2 from dropping from the split core 1 due to external vibration or the like.
Further, since the fixing member 4 is sandwiched between the split core 1 and the coil body 2 on the inner peripheral side of the coil body 2 to be fixed, the fixing member 4 itself does not fall off.
In addition, since the thin fixing member 4 can be bent in the flatwise direction as the fixing structure of the coil body 2, the bending process can be facilitated, and it can be bent with high accuracy and strength.
As described above, an armature having a reduced material, durability, energy saving, decomposability, separability, and high productivity can be provided.
In the present embodiment, the split iron core 1 has been described as having a laminated structure, but the same effect can be obtained even with a single split iron core.

Embodiment 2. FIG.
Hereinafter, the armature and the manufacturing method thereof according to the second embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 16 is a perspective view of the armature 200.
FIG. 17 is a partial perspective view of the coil body 202 in which the periphery of the coil 21 is molded with an insulating resin and integrated.

Inside the molded coil body 202, the tooth portion 11b of the split core 1 to which the fixing member 4 is joined is inserted, and the coil body holding portion 42 of the fixing member 4 is bent in the axial direction to be plastically deformed.
Others are the same as in the first embodiment.
As the resin, a thermoplastic resin or a thermosetting resin containing a filler such as alumina in order to improve the thermal conductivity is used.

According to the armature 200 according to the second embodiment of the present invention, the same effects as those described in the first embodiment can be obtained.
Moreover, the heat dissipation of the coil 21 can be improved by molding.
Furthermore, since the coil body 202 is molded as a whole, it does not deform.
As a result, when the coil body holding portion 42 of the fixing member 4 is bent, the coil body 202 does not extend in the longitudinal direction, the adhesion between the two is improved, and the heat dissipation is also improved as compared with the case where an insulating sheet is used. It can be improved.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

100, 200 armature, 130 stator, 1 split core, 1g slot,
11a Yoke part, 11b Teeth part, 11d, 11e, 11f
2,202 coil body, 21 coil, 21a coil end part,
21b Slot storage part, 21c terminal line, 22 insulator,
22a Coil receiving portion, 22b Outer flange, 22c Inner flange, 22d Groove, 23 Insulating sheet, 23a Teeth insulating portion, 23b Yoke insulating portion, 23c Teeth tip insulating portion,
23d interphase insulating part, 3 frame, 4, 44, 45 fixing member,
41 split iron core fixing part, 42, 42a, 42b coil body holding part, 44g through long hole,
4d, 4e, 4f Caulking dowels, 4k cutouts, 5 retaining pins.

Claims (10)

A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
The armature which has provided the notch part in the both ends on the boundary line of the said split iron core fixing | fixed part and the said coil body holding | maintenance part of the said fixing member, respectively. A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
An armature including a plurality of the coil body holding portions with respect to the divided core fixing portion. A split iron core equally divided in the circumferential direction of the stator and having a yoke part and a tooth part;
In the armature provided with a coil body disposed on the outer periphery of the shaft portion of the teeth portion of the divided core,
A split core fixing portion joined to an axial end surface of the stator of the split core;
A fixing member having a coil body holding portion for holding a radially inner side surface of the stator of the coil end portion of the coil body;
At both ends of the fixing member on the boundary line between the split core fixing part and the coil body holding part, a notch is provided,
An armature including a plurality of the coil body holding portions with respect to the divided core fixing portion. The armature according to any one of claims 1 to 3, wherein the fixing member is an L-shaped plate including the split core fixing portion and the coil body holding portion. The armature according to any one of claims 1 to 4, wherein the coil body includes an insulating member that insulates the coil and the split iron core. The armature according to claim 5, wherein a groove portion into which the coil body holding portion is fitted is provided on a side surface of the insulating member. The said insulating member is provided with the insulator which covers the axial direction both end surface of the said stator of the said teeth part of the said split iron core, and the insulating sheet which covers the storage part in the slot of the said coil. Armature. The armature according to claim 5 or 6, wherein a periphery of the coil is molded with an insulating resin that is the insulating member. The armature according to any one of claims 5 to 8, wherein the coil is an edgewise coil. A fixing member joining step in which the planar fixing member is joined to the axial end surface of the stator of the split iron core so that the coil body holding portion protrudes from the teeth portion to the inside of the stator;
A coil body mounting step of mounting the coil body on a tooth portion of the split core;
The armature according to any one of claims 1 to 9 , further comprising a fixing member bending step of bending the coil body holding portion of the fixing member substantially at a right angle to fix the coil body to the divided iron core. Manufacturing method.

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