JP6076179B2 - Split stator core, stator having the split stator core, rotating electric machine having the stator, and method of manufacturing the split stator core - Google Patents

Description

  The present invention relates to a split stator core of a rotary electric machine such as a motor or a generator, a stator including the split stator core, a rotary electric machine including the stator, and a method of manufacturing the split stator core. Is.

Conventionally, in an inner rotor type motor such as a brushless DC motor, a concentrated winding structure in which a coil is wound around a magnetic pole of a stator is employed.
The stator having this structure employs a manufacturing method in which a coil is wound around a stator core divided in order to wind the coil with high density and then assembled.
The divided stator cores are formed by punching out all the magnetic poles from the strip-shaped magnetic steel sheet, but the layout at the time of punching may be arranged in a zigzag manner so as to face each other. Has been done. In a rotating electrical machine employing such a split stator core, in order to improve the yield of the core material, it has a substantially T-shape and is split and fixed in a plurality of rings to form one stator core. A yoke portion that forms a magnetic path in the circumferential direction of the core and a magnetic pole tooth provided with protrusions protruding at both ends in the circumferential direction at the tip, and on the inner peripheral portion of the yoke portion on the magnetic pole tooth side, A substantially triangular first notch is provided, and two rows of divided stator cores are disposed between one row of adjacent magnetic teeth when one of the divided stator cores is punched. Are arranged so as to face each other, and the notch is punched out in accordance with the end of the electromagnetic steel pole in the width direction (Patent Document 1).
In addition, a plurality of divided cores are used in which an annular laminated core is laminated on a divided laminated core divided into a plurality in the circumferential direction, and a wide portion is formed on the outer periphery in the radial direction and a narrow portion is formed on the inner side in the radial direction. In the method for manufacturing a piece, adjacent divided core pieces are arranged so that the center line in the radial direction of each divided core piece is parallel and the side end portion of the narrow portion of the divided core piece adjacent to the side end portion of the wide portion abuts. It is shown that there are a step of cutting a group of iron core pieces arranged alternately in a strip material, and a pressing step of punching each divided core piece (Patent Document 2).
Furthermore, a technique is shown in which the yoke part is divided into two parts and separated from the magnetic pole part (Patent Document 3).

JP 2011-244687 A JP 2010-213505 A JP 2003-274583 A

  However, the technique disclosed in Patent Document 1 provides the first notch on the inner peripheral portion of the yoke portion on the side of the magnetic pole teeth. Therefore, depending on the notch shape, the magnetic circuit may be adversely affected. There is a possibility of hindering the improvement of characteristics. Further, when winding the coil around the magnetic teeth, the arc-shaped yoke hinders the supply of the coil lead wire, so that there is a problem that high-density coil winding up to the base of the magnetic teeth cannot be performed. In addition, the technique disclosed in Patent Document 2 does not provide a sufficient material yield improvement depending on the shape of the tip of the magnetic pole, or is assembled in an annular stator with a small number of magnetic poles and a narrow magnetic pole tip. When the space between the adjacent magnetic poles is large, there is a problem that when this space is viewed from the material surface, a useless region is widened, and sufficient yield improvement cannot be obtained. Furthermore, the technique disclosed in Patent Document 3 has a configuration in which a magnetic pole portion is joined to a yoke having a two-part structure, and there is a problem that sufficient rigidity and assembly accuracy cannot be obtained.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems. A split stator core having an iron core shape that can be provided with a coil wound at high density and has improved material yield, and the split It is an object of the present invention to provide a stator including a stator core, a rotating electric machine including the stator, and a method of manufacturing the split stator core.

A first invention is a substantially T-shaped split stator core formed by punching and laminating thin electromagnetic steel sheets and integrating a yoke and magnetic teeth, wherein the yoke has a predetermined thickness and a circular shape. It has an arc shape, and the magnetic pole teeth protrude from the inner peripheral portion of the yoke to the inner diameter side of the stator, and are provided with tip portions extending in the circumferential direction, on the inner peripheral portion of the yoke located on the left and right sides of the magnetic pole teeth. The provided notch part extends from the stepped part of the magnetic teeth to the end surface of the arc part of the yoke, and has a configuration in which an insertion piece is fitted into the notch part.

  According to a second aspect of the present invention, there is provided a stator in which a plurality of split stators each having a coil provided on the split stator core according to the first aspect of the present invention are annularly coupled. 3rd invention is the rotary electric machine provided with the stator based on 2nd invention, 4th invention is the manufacturing method of the split stator core which concerns on 1st invention.

  In the split stator core manufacturing method according to the first invention and the split stator core manufacturing method according to the fourth invention, the material yield when punching the split stator core from the thin electromagnetic steel sheet is improved, and resource saving is achieved. In addition, there is an effect that an inexpensive split stator core can be provided.

  Since the stator according to the second invention employs the above-described configuration, the rigidity can be increased, and the rotating electrical machine according to the third invention can wind the coil over the entire magnetic teeth. Thus, a high-density coil winding can be obtained, and the output characteristics of the rotating electrical machine are improved.

FIG. 3 is a front view of the stator according to the first embodiment. FIG. 3 is a diagram illustrating a split stator core and a split stator according to the first embodiment. FIG. 3 is a diagram showing a coupling state of the stator according to the first embodiment. FIG. 6 is a diagram showing a coil winding operation according to the first embodiment. It is a figure which shows the state which fits the insertion piece by Embodiment 1. FIG. FIG. 6 is a diagram showing a layout for punching a split stator core according to the first embodiment. FIG. 6 is a diagram showing a split stator core according to a second embodiment. FIG. 10 is a diagram showing a layout for punching a split stator core according to a second embodiment. FIG. 6 is a diagram showing a split stator core according to a third embodiment. FIG. 10 is a diagram showing a split stator according to a third embodiment. FIG. 10 is a diagram showing a layout for punching a split stator core according to a fourth embodiment. It is a figure which shows the coil by Embodiment 5. FIG.

Embodiment 1 FIG.
Hereinafter, a rotating electrical machine provided with a split stator according to the present invention will be described.
FIG. 1 is a plan view showing a stator 100 of a rotating electrical machine according to Embodiment 1, and a nine-pole split stator 50 formed by laminating thin electromagnetic steel plates is integrally coupled. As shown in FIG. 2 (c), the split stator 50 is provided with a coil 4 formed by winding a conductor around a split stator core 30 for each pole, and a convex provided on a yoke 1 described later. The portion 1d and the recess 1e are tightly coupled by the coupling portion 50a, and the rigidity of the stator 100 as a whole is maintained.
FIG. 2 shows a planar shape of the split stator core 30.
As shown in FIG. 2A, for example, a split stator core 30 made by punching out a magnetic steel sheet of about 0.1 to 0.7 mm is formed by the yoke 1, the magnetic teeth 2 and the insertion piece 3 as shown in FIG. As shown in FIG. The yoke 1 and the magnetic teeth 2 are integrally connected. A tip 2a is provided on the side of the magnetic teeth 2 facing the rotor (not shown), and protrusions 2b are provided at both ends in the circumferential direction. ing.
The yoke 1 has an arc shape having a predetermined thickness T, and since the stator 100 illustrated in FIG. 1 is a nine-pole split stator 50, the arc angle is 40 ° and the end face of one arc portion. A convex portion 1d is formed in 1k, a concave portion 1e is formed in the end surface 1k of the other arc portion, a dovetail groove 1c is formed in the arc central portion of the yoke outer peripheral portion 1a, and the magnetic pole teeth 2 of the yoke inner peripheral portion 1b A notch 1 f is formed through a stepped portion 1 g that is located on both sides and is connected to the magnetic pole teeth 2. The insertion piece 3 is densely inserted into the notch 1f through a step 1g.
The sum t1 + t2 of the thickness t1 of the yoke 1 and the depth t2 of the notch 1f at the location where the notch 1f is provided corresponds to the thickness T of the yoke 1.
The insertion piece 3 fitted into the notch 1f is formed by punching using the space between the yoke inner peripheral portion 1b and the tip 2a, that is, the space in which the coil 4 shown in FIG. 2C is provided. . As will be described in detail later, the coil 4 is provided with ground insulation 4a on the split stator core 30 and is wound and mounted in the same manner as a normal split core, and is integrated with the split stator core 30 so that the split stator 50 is provided. Form.
As described above, the split stator 50 is closely coupled to the adjacent split stator 50 at the connecting portion 50a shown in FIG. 1, and is press-fitted and fixed to the cylindrical frame 51 as shown in FIG. The split stator core 30 and the insertion piece 3 are joined by caulking or the like so as to have a predetermined axial thickness after being punched out by an electromagnetic steel plate. In the split stator 50, the coupling portion 50a is pressed against each other by the radial tightening force exerted from the frame 51, and the rigidity is ensured.
Since the split stator core 30 according to the first embodiment has a substantially T shape in which the yoke 1 and the magnetic teeth 2 are integrated, it is assembled to the stator 100 shown in FIG. And the roundness of the tip 2a can be maintained with high accuracy.

Next, a state where the coil 4 is wound around the split stator core 30 is shown in FIG. In this case, the insertion piece 3 is not fitted to the split stator core 30, so that the conductive wire 4 b led out from the winding arm 40 is connected to the ends of the arc portion shown in FIG. It becomes possible to wind the magnetic teeth 2 without interfering with 1k, and it is possible to form the coil 4 wound up to the boundary 1h between the yoke 1 and the magnetic teeth 2 as shown in FIGS. Become. As a work procedure, ground insulation 4a made of a non-woven material or the like is attached to the split stator core 30. The yoke 1 side of the ground insulation 4a can be bent flexibly. The coil 4 is formed by rotating the winding arm 40 of the winding machine with respect to the ground insulation 4a and winding the conductive wire 4b.
Subsequently, as shown in FIG. 5, the split stator 50 is generated by fitting the insertion piece 3 into the notch 1f.
As described above, since the structure of the split stator core 30 according to the first embodiment is provided, the coil 4 is wound over the entire magnetic teeth 2, and a high-density winding can be obtained. The output characteristics of the electric machine are improved. In order to fit the insertion piece 3 into the notch 1f, an insertion space can be secured using a dedicated tool.

FIG. 6 shows a layout when the split stator core 30 according to the first embodiment is punched from a thin electromagnetic steel sheet 31. The split stator cores 30 are punched out in a zigzag pattern facing in opposite directions.
At this time, the end portions 2a of each other can be arranged close to each other in the vicinity of the notch portion 1f. As a result, the material width MW of the electromagnetic steel sheet 31 can be reduced as compared with the conventional case, the material used is reduced, and further insertion Since the piece 3 is punched by using the space area between the yoke inner peripheral portion 1b and the tip portion 2a, which has been conventionally scrapped, the yield is improved and resource saving is achieved. As a result, an inexpensive rotating electrical machine is provided. Is possible.
FIG. 2 shows an example of the stator 100 that is assembled by press fitting by providing convex portions 1d and concave portions 1e at both ends of the yoke 1. However, the outer circumferences of the yokes at both ends of the yoke 1 without providing the convex portions 1d and concave portions 1e. The part 1a may be joined by welding or the like at the joining part 50a shown in FIG.

Embodiment 2. FIG.
Next, the shape of the split stator core 30 according to the second embodiment is shown in FIG. As shown in FIG. 7A, the notch 1f of the yoke 1 of the split stator core 30 is provided with a fitting recess 1j, and the insertion piece 3 is provided with a fitting protrusion 3a. Therefore, as shown in FIG. 7B, when the insertion piece 3 is coupled to the notch portion 1f, it can be easily assembled by fitting the fitting convex portion 3a and the fitting concave portion 1j. Next, FIG. 8 shows a layout when the split stator core 30 according to the second embodiment is punched from the electromagnetic steel sheet 31. Similar to the first embodiment described above, it is possible to arrange the tip portion 2a and the notch portion 1f close to each other, thereby reducing the material used and improving the yield. In addition, since the yoke 1 and the insertion piece 3 can be easily integrated using the fitting recess 1j and the fitting projection 3a, handling property such as conveyance by the integration is improved, and the winding process and the stator assembly process. As a result, the cost can be reduced and the rigidity and accuracy of the stator can be improved.

Embodiment 3 FIG.
The shape of the split stator core 30 according to Embodiment 3 is shown in FIG. As shown in FIG. 9A, the connecting piece 30b is provided in which the insertion piece 3 is connected to the stepped portion 1g without being separated from the yoke 1. With this configuration, the insertion piece 3 is bent toward the notch 1f around the connecting portion 30b, and the insertion piece 3 is fitted into the notch 1f as shown in FIG. 9B.
In addition, in the insertion piece 3, the left-side insertion piece 3 is provided with a tip convex portion 3 b and a concave portion of the yoke 1 in FIG. 9A arranged on the convex portion 1 d side provided on the arcuate end surface 1 k of the yoke 1. Since the insertion piece 3 arranged on the 1e side is provided with a tip recess 3c, when the adjacent split stators 50 are assembled as shown in FIG. 10, the tip projection 3b and the tip recess 3c are fitted. As a result, the stator 100 having higher rigidity and higher accuracy can be obtained. In FIG. 10, the description of the coil 4 is omitted. The configuration of the yoke 1 and the insertion piece 3 of the third embodiment may be combined with the configuration using the fitting concave portion 1j and the fitting convex portion 3a of the second embodiment described above. Furthermore, the third embodiment can also pierce the split stator core 30 from the electromagnetic steel sheet 31 with a layout substantially equivalent to that shown in FIG. 8 shown in the second embodiment, and has the same effect as the second embodiment. .

Embodiment 4 FIG.
FIG. 11 shows a layout when the split stator core 30 according to the fourth embodiment is punched. Adjacent ones of the split stator cores 30 are connected by a connecting portion corresponding to the connecting portion 50a when the split stator 50 is formed. That is, the yokes 1 of the divided stator cores 30 adjacent to each other are not separated by punching but are coupled by the coupling part 50a. Accordingly, there is an advantage that the split stator core 30 of the upward portion shown in FIG. 11 and the split stator core 30 of the downward portion can be integrally handled, respectively. Winding work can be continuously performed on the divided stator core 30 of the site, and the efficiency of the winding process can be improved. Furthermore, the stator 100 can be easily assembled by welding the joint portion 50a when the stator 100 is joined. Also in the fourth embodiment, the protrusion 1d and the recess 1e provided on the yoke 1 of the first to third embodiments described above, and the insertion piece 3 and the notch 1f of the yoke 1 shown in the first embodiment. Further, the fitting convex portion 3a of the insertion piece 3 shown in the second embodiment and the fitting concave portion 1j of the yoke 1, the connecting portion 30b shown in the third embodiment, the tip convex portion 3b of the insertion piece 3, and the tip concave portion 3c. These configurations may be combined with Embodiment 4 as appropriate.

Embodiment 5. FIG.
The fifth embodiment relates to the configuration of the coil 4 and particularly relates to the divided stator 50 in the rotating electric machine that does not use the insertion piece 3 in the divided stator core 30 shown in the first embodiment. This configuration is shown in FIG.
As can be seen from FIG. 12, the coil 4 of the fifth embodiment is formed by winding a conductive wire 4b from the stepped portion 1g of the yoke 1 to the notch portion 1f of the split stator core 30 to form the coil 4. It is what.
Accordingly, the split stator 50 having an increased number of coil turns is obtained. The feature of adopting this configuration is that the split stator core 30 obtained by using the same electromagnetic steel sheet casting die as in the first embodiment is used, and has characteristics different from those of the rotary electric machine in the first embodiment. The stator 100 is obtained. That is, it is possible to obtain a stator 100 having two different characteristics in one whole type, and also to share a winding machine and a stator assembly facility, and to create a rotating machine having different characteristics without requiring capital investment. effective.

  It should be noted that within the scope of the present invention, the embodiments can be freely combined, or the embodiments can be appropriately modified or omitted.

1 yoke, 1a yoke outer peripheral part, 1b yoke inner peripheral part, 1d convex part, 1e concave part,
1f notch, 1j fitting recess, 1k arc end face, 2 magnetic teeth,
2a tip part, 3 insertion piece, 3a fitting convex part, 3b tip convex part, 3c tip concave part,
4 coils, 30 split stator core, 30b connecting part, 50 split stator,
50a coupling part, 100 stator.

Claims (10)

It is a substantially T-shaped split stator core formed by punching and laminating thin electromagnetic steel sheets, and a yoke and magnetic pole teeth integrated, wherein the yoke has a predetermined thickness and an arc shape, pole tooth tip portion which extends in the circumferential direction with projecting the inner peripheral portion or al stator inner diameter side of the yoke is provided on the inner peripheral portion of the yoke located on the left and right sides with respect to the pole tooth The notch portion is extended from the stepped portion of the magnetic pole teeth to the end surface of the arc portion of the yoke, and has a configuration in which an insertion piece is fitted into the notch portion. Child iron core. 2. The split stator core according to claim 1 , wherein a convex portion is provided on one end surface of the arc portion of the yoke, and a concave portion is provided on the end surface of the other arc portion. A fitting recess is provided in the notch of the yoke, and a fitting protrusion is provided on the side of the insertion piece in contact with the notch of the yoke, and the fitting is provided in the fitting recess. The split stator core according to claim 1 or 2 , wherein a fitting convex portion is fitted. The insertion pieces on both sides of the magnetic pole teeth are connected to the connection portion where the magnetic pole teeth are connected to the inner peripheral portion of the yoke without being disconnected from the inner peripheral portion of the yoke, and the connection of the insertion pieces is performed. A tip convex portion is provided on the end surface of one insertion piece located on the convex portion side provided on the end surface of the circular arc portion of the yoke, and a tip concave portion is provided on the end surface of the other insertion piece. The split stator core according to claim 2 or 3 , wherein the split stator core is provided. A stator in which a plurality of split stators each having a coil provided on the split stator core according to claim 1 are formed in a ring shape. A plurality of split stators each having a coil provided on the split stator core according to claim 2 or 3 are formed by fitting the convex portions and concave portions of the yoke into an annular shape. To be a stator. A plurality of split stators having coils on the split stator iron core according to claim 4 , wherein the convex part and the concave part of the yoke are fitted together, and the convex part of the tip is fitted into the concave part of the tip of the insertion piece. A stator characterized by being joined in a ring shape. A rotating electrical machine comprising the stator according to any one of claims 5 to 7 . The stator according to claim 5, wherein the joints of the outer peripheral portions of the yokes of the plurality of split stators forming the stator are joined by welding. Rotating electric machine. It is a manufacturing method of the split stator core of any one of Claims 1-4 , Comprising: The said split stator core arrange | positioned in 2 rows at the time of the punching of the thin electromagnetic steel plate of the said split stator core Are arranged in a zigzag manner so that the tip portions of the magnetic pole teeth are close to the region of the notch portion of the yoke, and the insertion piece is from a space region between the adjacent magnetic pole teeth. A method of manufacturing a split stator core, characterized by being punched.

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