JP6210003B2 - Stator core, rotating electric machine, and stator core manufacturing method - Google Patents

Description

  The present invention relates to a stator core applied to a rotating electrical machine (a motor, a generator, or a motor / generator), a rotating electrical machine including the stator core, and a method for manufacturing the stator core.

  Conventionally, a magnetic core (stator core) is formed by laminating a plurality of flat electromagnetic steel sheets punched into a predetermined shape in the thickness direction, and an armature is formed by winding a coil around the magnetic core. Has been done. In order to reduce the labor of manufacturing and assembling such an armature, electrical steel sheets are joined together by caulking in advance. For example, Patent Document 1 relates to an armature of an axial gap type rotating electrical machine. A technique for joining magnetic steel sheets forming magnetic cores by V-caulking is disclosed.

JP 2011-45187 A

  However, caulking has a high bonding strength and can be easily performed by pressing, but on the other hand, it causes distortion in the surface of the electromagnetic steel sheet, thereby reducing the magnetic permeability of the electromagnetic steel sheet (decreasing the magnetic flux density) and increasing the iron loss. Therefore, it is one of the causes of deterioration of the magnetic properties of the magnetic core. Therefore, in a rotating electrical machine for a vehicle that is small and requires high output, it is required to improve the efficiency of the rotating electrical machine by improving such deterioration of magnetic characteristics.

  This invention is made | formed in view of said situation, and it aims at providing the technique which contributes to the high efficiency of a rotary electric machine.

In a stator of a rotating electric machine, a cylindrical member (bobbin) formed of an insulating material is mounted on a stator core, and a coil is wound around the outside of the bobbin to electrically insulate the stator core from the coil. Is adopted. The present invention focuses on this point. That is, the stator core of the rotating electrical machine according to the present invention is formed of a core body formed by laminating a plurality of steel plates having a predetermined shape, and an insulating resin material. A bobbin that surrounds the core body in a state in which an end portion in a direction orthogonal to the laminating direction is exposed and a coil is wound on the outside, and the core body includes a plurality of steel plates each having the same shape. A plurality of laminated bodies are laminated in the laminating direction, and each laminating body has mutually different dimensions in the width direction perpendicular to the laminating direction and is on one side of the laminating direction. than laminate positioned are set towards the laminate positioned on the other side the width dimension is large, and the core body and the bobbin are integrally molded by insert molding, the core body The end portion protrudes outward from the bobbin, and the stepped portion of the laminated body at the end portion is filled with a filling member made of a resin material, so that flat surfaces are formed on both sides in the width direction of the end portion. It is what.

  According to such a configuration, since a plurality of steel plates can be integrated without joining the steel plates by caulking, it is possible to avoid deterioration of the magnetic properties of the stator core due to distortion in the steel plates. In addition, since the resin material penetrates between adjacent steel plates and the steel plates are joined together, a high joint strength can be obtained, and furthermore, the bobbin and the core body can be closely adhered without any gap, so that the core body to the bobbin Heat conductivity can also be improved. Moreover, since the steel plates are integrated using the bobbin, there is no need to provide a dedicated member for the integration, and the steel plate integration and the bobbin mounting are performed at the same time at the time of forming. Good quality.

In addition , the manufacturing cost of the stator core can be suppressed while increasing the volume of the core body. That is, since the stator is configured by arranging a plurality of stator cores on the circumference, it is advantageous from the viewpoint of increasing the magnetic flux density that the core body has a shape in which the volume increases from the radially inner side to the outer side. In this case, if the core body is formed by laminating a plurality of steel plates having different sizes, the number of steel plate press dies is required for the number of steel plates to be laminated. On the other hand, according to the above configuration, since the size of the steel plate is concentrated, the number of dies can be reduced, and thus the manufacturing cost can be suppressed while securing the volume of the core body. Become.

Moreover , since the level | step difference formed by each laminated body is eliminated, the shape of the whole said edge part containing the said filling member can be simplified.

  On the other hand, in the stator core manufacturing method of the present invention, a preparation step of preparing a plurality of steel plates each having a predetermined shape and provided with positioning notches at predetermined positions on the outer peripheral portion, and the notches arranged in a row. By aligning and laminating the plurality of steel plates, storing the laminated steel plates in a mold in a state of being positioned using the notches, and performing the insert molding. And a forming step of forming the bobbin around the steel plate.

  According to this manufacturing method, it is possible to stably manufacture a good stator core having a core body in which a plurality of steel plates are appropriately arranged.

  As described above, according to the present invention, it is possible to avoid the deterioration of the magnetic characteristics due to the distortion of the core body (steel plate) of the stator core, thereby increasing the efficiency of the rotating electrical machine.

It is a disassembled perspective view which shows the rotary electric machine (rotary electric machine to which the stator core of this invention is applied) which concerns on 1st Embodiment of this invention. It is a perspective view which shows the stator integrated in a rotary electric machine. It is sectional drawing (III-III sectional view taken on the line of FIG. 2) of a rotary electric machine. It is sectional drawing (IV-IV sectional view taken on the line of FIG. 3) of a rotary electric machine. (A) is a top view which shows a stator core, (b) is the same side view (b arrow view of (a)), (c) is the same front view (a arrow view of (a)). is there. It is sectional drawing which shows the modification of a rotary electric machine. It is sectional drawing which shows the modification of a rotary electric machine. It is a schematic diagram explaining the structure of a stator. It is a schematic diagram explaining the structure of a stator. It is a figure which shows the modification of a stator core, (a) is a top view, (b) is a side view (c arrow line view of (a)). It is a disassembled perspective view which shows the rotary electric machine which concerns on 2nd Embodiment of this invention. It is a perspective view which shows the stator integrated in a rotary electric machine. It is sectional drawing (XIII-XIII sectional view taken on the line of FIG. 12) of a rotary electric machine. It is sectional drawing which shows the modification of a rotary electric machine. It is a figure which shows the modification of the stator integrated in the axial gap type rotary electric machine which concerns on 2nd Embodiment of this invention, (a) is a perspective view, (b) is XV-XV sectional view taken on the line of (a). ).

  Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

(First embodiment)
FIG. 1 is an exploded perspective view of the rotating electrical machine according to the first embodiment of the present invention. A rotating electrical machine 1A shown in the figure is interposed between a rotor 2 having a rotating shaft 10 as a center and rotor rotor bodies 12A and 12B described later of the rotor 2, and the axis of the rotating shaft 10 with respect to the rotor bodies 12A and 12B. This is a so-called axial gap type rotating electrical machine including a stator 4 facing the direction with a predetermined interval and a housing 6 in which the rotor 2 and the stator 4 are accommodated. In the following description, the direction parallel to the rotation shaft 10 is referred to as “axial direction”, the direction orthogonal to the rotation shaft 10 is referred to as “radial direction”, and the rotation direction of the rotation shaft 10 (rotor 2) is referred to as “circumferential direction”. .

  The rotor 2 includes a pair of disk-shaped rotor bodies 12A and 12B that are arranged to face each other at a predetermined interval, and a rotating shaft 10 that passes through the centers of the rotor bodies 12A and 12B. Each rotor body 12A, 12B is fixed to a rotating shaft 10, and the rotating shaft 10 is supported by the stator 4 via a bearing 28 described later. With this configuration, the rotor 2 is rotatably supported with respect to the stator 4.

  Each of the rotor bodies 12A and 12B includes a rotor disk 14 that also serves as a back yoke and a plurality of permanent magnets 16 that are fixed to the rotor disk 14 in a state of being arranged in the circumferential direction. Each permanent magnet 16 is a plate-like magnet, and is fixed to a surface of the rotor disk 14 that faces the stator 4. The permanent magnet 16 of the rotor body 12A on the one side and the permanent magnet 16 of the rotor body 12B on the other side are mirror-symmetrical. In this example, for the purpose of reducing cogging torque, etc., it is slightly rhombus in plan view. It has a close shape. Note that the number and arrangement of the permanent magnets 16 in the rotor main bodies 12A and 12B are the same.

  The stator 4 is disposed between the rotor bodies 12A and 12B. As shown in FIG. 1, the stator 4 includes a plurality of stator cores 22 arranged in the circumferential direction, a coil 23 mounted (wound) on each stator core 22, and a pair of support members that support the stator core 22 from both sides in the axial direction. 26, an inner cylindrical member 20 that is disposed inside the plurality of stator cores 22 and connects the pair of support members 26, and a seal member 24 that is interposed between each support member 26 and the stator core 22, respectively. including.

  2 to 4 show the stator 4, and FIGS. 5A to 5C each show the stator core 22.

  The stator core 22 includes a core body 40 and a bobbin 44 attached to the core body 40. The core body 40 has a block-like structure in which a plurality of electromagnetic steel plates 41 pressed into a predetermined shape are laminated in the radial direction. More specifically, the core body is configured by laminating a plurality of laminated bodies g1 to g6 in which a plurality of electromagnetic steel plates 41 each having the same shape are laminated, and each laminated body. g1 to g6 are different from each other in the width direction perpendicular to the radial direction (the left-right direction in FIG. 5A), and the laminated body located radially outside the laminated body located radially inside is more preferable. The dimension in the width direction is set large. Thereby, as shown in FIG. 5A, the core main body 40 is formed in a substantially trapezoidal shape that is tapered from the radially outer side to the inner side in a plan view.

  Each electromagnetic steel plate 41 constituting the core body 40 is integrally held by a bobbin 44. That is, the bobbin 44 is formed of an insulating resin material. In this example, the stator core 22 is molded by insert molding using the core body 40 as a metal part and the bobbin 44 as a resin part. That is, the core body 40 and the bobbin 44 are integrally formed so as to surround the core body 40 with the bobbin 44.

  The resin material includes fillers such as glass fiber, carbon fiber, whisker, and talc, for example, so that the bobbin 44 has a linear expansion coefficient substantially equal to the linear expansion coefficient of the core body 40. 44 is formed.

  Reference numerals 42 shown in FIGS. 5A and 5C are notches for positioning, and are formed at the outer peripheral portion of each electromagnetic steel plate 41, in this example, at both ends in the axial direction and in the central portion in the width direction. Has been. This notch 42 positions each electromagnetic steel plate 41 with respect to the mold during the insert molding. This point will be mentioned later.

  As shown in FIGS. 5B and 5C, the bobbin 44 has a cylindrical portion 46 surrounding the core body 40 and flanges 47 formed at both upper and lower ends thereof, and illustration thereof is omitted. However, the coil 23 is wound on the outer peripheral surface of the cylindrical portion 46.

  As shown in FIG. 5A, each flange 47 of the bobbin 44 is formed in a substantially fan shape in plan view. Of each flange portion 47, one end side in the circumferential direction is formed with a convex portion 47a that protrudes in the same direction and extends in the radial direction, and the other end side has a diameter with which the flange portion 47 can be fitted. A recess 47b extending in the direction is formed. That is, the stator cores 22 are arranged side by side and the bobbins 44 are fitted. Specifically, the stator cores 22 are connected by fitting the convex portions 47a to the concave portions 47b. In this case, the flange portions 47 of the adjacent stator cores 22 (bobbins 44) are connected in a liquid-tight state by fitting the convex portions 47a and the concave portions 47b.

  The plurality of stator cores 22 are connected in an annular shape as shown in FIG. 2 by fitting the bobbins 44 of the adjacent stator cores 22 together. In this example, the convex portion 47a and the concave portion 47b of the bobbin 44 correspond to the connecting portion of the present invention.

  The pair of support members 26 are disk-shaped members made of a non-magnetic material (such as austenitic stainless steel or aluminum) and have the same configuration.

  The support member 26 has an outer diameter dimension equivalent to an inner peripheral surface (an inner peripheral surface other than the small-diameter portion 7a) of the cylindrical housing 7 which will be described later, and a shaft hole 30 through which the rotary shaft 10 penetrates at the center. Is formed. A boss portion 32 protrudes outwardly on the surface of the support member 26 facing the rotor main bodies 12A and 12B so as to surround the shaft hole 30, and a bearing 28 is provided in the boss portion 32. Is press-fitted.

  Each support member 26 is provided so as to sandwich an annularly connected stator core 22 (hereinafter referred to as “stator core connection body” for convenience) from both sides in the axial direction. More specifically, the support member 26 includes a plurality of window portions 34 having a shape corresponding to the core body 40 around the shaft hole 30. On the other hand, as shown in FIG. 4, the core body 40 of the stator core 22 is provided with a tooth portion 40 a that protrudes outward in the axial direction from the bobbin 44, and the tooth portion 40 a fits into the window portion 34. Thus, each support member 26 is overlapped on both sides of the stator core coupling body. As described above, the teeth 40a of the core body 40 are fitted into the windows 34 of the support members 26, so that the end surfaces of the core bodies 40 of the stator cores 22 face the rotor bodies 12A and 12B through the windows 34. The stator cores 22 are positioned with respect to the support member 26.

  As shown in FIG. 4, the inner peripheral surface of the window portion 34 of the support member 26 and the outer peripheral surface of the tooth portion 40 a of the core body 40 are tapered surfaces, whereby the stator core coupling body (stator core 22) is formed. When sandwiched from both sides, the teeth 40a are guided by the tapered surface of the window 34 while being guided into the window 34 along the tapered surface, and the stator core 22 and the support member 26 are positioned by this guidance.

  In addition, the said sealing member 24 which seals between each support member 26 and a stator core coupling body is pinched | interposed between each support member 26 and a stator core coupling body. The seal member 24 is a circular plate-like member formed of, for example, rubber or synthetic resin, and similarly to the support member 26, a shaft hole 24a is formed at the center thereof, and the shaft hole 24a is formed around the shaft hole 24a. A plurality of window portions 24b having a shape corresponding to the core body 40 of each stator core 22 are formed. That is, the core body 40 of each stator core 22 is fitted to the window portion 34 of the support member 26 through the window portion 24 b of the seal member 24.

  The inner cylinder member 20 is disposed inside the stator core coupling body. The inner cylinder member 20 is formed of a nonmagnetic material (austenitic stainless steel, aluminum, or the like) like the support member 26. As shown in FIG. 3, the inner cylinder member 20 is disposed between the pair of support members 26, and is fixed to each support member 26 via a seal member 24 with a bolt B.

  The housing 6 includes a cylindrical housing 7 to which the rotor 2 and the stator 4 are assembled, and a pair of disk-shaped end covers 8 that closes both axial ends of the cylindrical housing 7.

  As shown in FIG. 3, a small-diameter portion 7a whose inner diameter is set smaller than other portions is formed inside the cylindrical housing 7 and in the central portion in the axial direction. In the small-diameter portion 7a, The stator 4 is assembled. Specifically, the stator core connection body (stator core 22) is disposed inside the small diameter portion 7a, and the pair of support members 26 are overlapped so as to sandwich the stator core connection body and the small diameter portion 7a from both sides in the axial direction. In this state, the support members 26 are fixed to the small diameter portion 7a by bolts B from both axial sides.

  Then, the rotating shaft 10 of the rotor 2 is inserted into the bearing 28 of each support member 26 so as to pass through the center of the stator 4 assembled to the cylindrical housing 7 (small diameter portion 7a) and is prevented from coming off. Has been. Thereby, the rotor 2 is rotatably supported by the stator 4.

  A shaft hole 8a is formed at the center of each end cover 8, and the rotary shaft 10 of the rotor 2 is led out of the housing 6 through the shaft hole 8a.

  In the rotating electrical machine 1A configured as described above, an annular closed space in plan view is formed inside the housing 6 by the support members 26 of the stator 4, the inner cylinder member 20, and the housing 6 (small diameter portion 7a). Has been. A cooling liquid introduction port IP and a lead-out port OP are provided in the cylindrical housing 7 at positions opposite to each other in the radial direction across the closed space. Coolant is supplied. In other words, in this rotating electrical machine 1A, the coolant is circulated to the closed space by introducing the coolant from the introduction port IP to the closed space while being led to the outside through the lead-out port OP. It is comprised so that 23 may be cooled.

  The configuration of the rotating electrical machine 1A according to the first embodiment has been described above. The rotating electrical machine 1A has the following advantages.

  First, according to the stator core 22 of the rotating electrical machine 1A, as described above, the core main body 40 and the bobbin 44 are integrally molded, and thereby a plurality of electromagnetic steel plates 41 constituting the core main body 40 are integrated. Therefore, the electromagnetic steel sheet is not distorted as in the conventional stator core in which a plurality of electrical steel sheets are joined and integrated within the plane, and deterioration of the magnetic properties of the stator core due to the distortion of the electromagnetic steel sheet is suppressed. . Accordingly, the efficiency of the rotating electrical machine 1A can be increased by the amount that such deterioration of the magnetic characteristics is suppressed.

  Further, according to the configuration of the stator core 22 as described above, the resin material penetrates between the adjacent electromagnetic steel plates 41 and the electromagnetic steel plates 41 are joined to each other, so that the electromagnetic steel plates 41 are integrated with a relatively high joint strength. Further, it is possible to effectively prevent the coolant from leaking outside through the adjacent magnetic steel sheets 41. Furthermore, since the bobbin 44 and the core body 40 are in close contact with each other with no gap, heat transfer from the core body 40 to the bobbin 44 is improved. When the heat transfer is improved in this way, the heat generated in the core body 40 is efficiently radiated to the coolant via the bobbin 44 and the coil 23, so that the operating efficiency of the rotating electrical machine 1A is reduced due to the heat generation of the stator core 22. There is also an advantage that it can be effectively suppressed.

  In addition, according to the configuration of the stator core 22, the electromagnetic steel plate 41 is integrated using the bobbin 44, so that a dedicated member for integrating the electromagnetic steel plate 41 is not necessary. In addition, since the integration of the electromagnetic steel plate 41 and the formation (attachment) of the bobbin 44 are performed simultaneously by molding, for example, as compared with a case where a plurality of electromagnetic steel plates are integrated by caulking and a separately formed bobbin is assembled. The number of manufacturing steps for the stator core 22 can be reduced. Therefore, there is also an advantage that the productivity of the stator core 22 and thus the rotating electrical machine 1A can be improved.

  Further, according to the configuration of the stator core 22, as described above, the plurality of stator cores 22 can be connected to each other in an annular shape by fitting the flange portions 47 of the bobbin 44 together. Therefore, a dedicated connecting member for connecting the stator cores 22 is not necessary, and this also has the advantage that it contributes to the improvement of the productivity of the stator cores 22 and consequently the rotating electrical machine 1A and the reduction of manufacturing costs.

  Further, in the stator core 22, as described above, the core body 40 is configured by laminating a plurality of laminated bodies g1 to g6 in which a plurality of electromagnetic steel plates 41 each having the same shape are laminated in the radial direction. Therefore, there is an advantage that the manufacturing cost of the stator core 22 can be suppressed while increasing the volume of the core body 40. That is, since the stator 4 is configured by arranging the plurality of stator cores 22 on the circumference as described above, the core body 40 has a shape in which the volume increases from the radially inner side to the outer side to increase the magnetic flux density. It is advantageous from the viewpoint. In this case, if the core main body 40 is formed by laminating a plurality of steel plates having different sizes, the number of steel plates for the steel plates to be laminated is required and the manufacturing cost increases. On the other hand, according to the structure of the said embodiment, since the size of the electromagnetic steel plate 41 is collected, the number of metal mold | dies can be reduced. Therefore, it is possible to suppress the manufacturing cost while securing the volume of the core body 40.

  Further, according to the configuration of the stator core 22, the bobbin 44 is formed so that the linear expansion coefficient of the bobbin 44 is substantially equal to the linear expansion coefficient of the core body 40. The balance of thermal deformation can be maintained. Therefore, a gap is generated between the bobbin 44 and the core body 40 due to thermal deformation, and this causes a disadvantage that the heat transfer from the core body 40 to the bobbin 44 is reduced or the core body 40 is deformed. Can be suppressed.

  The above-described stator core 22 can be manufactured by the following method, for example. That is, a plurality of electromagnetic steel plates 41 (laminated bodies g1 to g6) having a predetermined shape and each having the notch 42 on the outer peripheral portion are prepared (preparation step). Then, the plurality of electromagnetic steel plates 41 are aligned and laminated so that the notches 42 of the electromagnetic steel plates 41 of the laminates g1 to g6 are arranged in a line, and the laminated electromagnetic steel plates 41 are used by using the notches 42. The insert molding is performed after being accommodated in a mold in a positioned state, thereby forming bobbins 44 around the plurality of electromagnetic steel plates 41 (laminated bodies g1 to g6) (molding step). According to such a manufacturing method, it is possible to stably manufacture the stator core 22 including the core body 40 in which a plurality of electromagnetic steel plates 41 (laminated bodies g1 to g6) are appropriately arranged. In this manufacturing method, a notch 42 is formed in the electromagnetic steel plate 41 in advance. Since the notch 42 is formed in the outer peripheral portion of the electromagnetic steel plate 41, the electromagnetic steel plate 41 is caulked with distortion in the plane. In comparison, the effect on magnetic flux formation is extremely low. Therefore, there is almost no deterioration of the magnetic characteristics of the rotating electrical machine 1A.

  The rotary electric machine 1A according to the first embodiment has been described above, but the following configuration (modification) may be employed in the rotary electric machine 1A.

  (1) In the above embodiment, the stator 4 is assembled to the cylindrical housing 7 by fixing each support member 26 to the small diameter portion 7a, but as shown in FIG. An outer cylinder member 36 is provided which is interposed in the portion and is fixed to each support member 26 by a bolt B. As shown in the figure, in a state where the stator 4 is fitted in the cylindrical housing 7, the outer cylinder member 36 is provided. May be fixed to the cylindrical housing 7 with bolts B. In this case, the small diameter portion 7a of the cylindrical housing 7 is not necessary.

  According to such a structure, there exists an advantage that the assembly | attachment property of the rotor 2 with respect to the housing 6 (cylindrical housing 7) improves. That is, in the configuration of the rotating electrical machine 1A shown in FIG. 3 and the like, it is necessary to sandwich the small diameter portion 7a of the cylindrical housing 7 from both sides in the axial direction by the support members 26 and fix the outer cylindrical member 36 to the small diameter portion 7a. The stator 4 cannot be assembled into the cylindrical housing 7 in a state where the stator 4 is completed in advance. For this reason, it is necessary to insert the stator 4 into the cylindrical housing 7 with one of the support members 26 removed, and to insert the other support member 26 into the cylindrical housing 7 from the opposite side. On the other hand, according to the configuration shown in FIG. 6, the stator 4 can be inserted into the cylindrical housing 7 and fixed in a state where the stator 4 is completed in advance. Therefore, it is not necessary to assemble the stator 4 in the cylindrical housing 7, and the assembling property of the rotor 2 to the housing 6 (cylindrical housing 7) is improved accordingly.

  (2) A guide plate for guiding the coolant to flow along a predetermined path may be provided in the closed space inside the stator 4. For example, as shown in FIG. 7, when the coolant passes between adjacent coils 23, the coolant flows in the circumferential direction while meandering in an annular closed space as indicated by an arrow in FIG. As described above, the guide plates 38a and 38b may be provided. According to such a configuration, the coolant can be surely passed through each coil 23. Furthermore, since the closed space is narrowly partitioned by the guide plates 38a and 38b, the flow path of the coolant is narrowed, so that the flow rate of the coolant flowing through the flow path is also increased. Therefore, the coil 23 can be efficiently cooled.

  However, if the guide plates 38a and 38b are provided on the inner cylinder member 20 and the cylindrical housing 7 (small diameter portion 7a) with the configuration of the stator 4 shown in FIG. 3, actual assembly becomes difficult. Therefore, when the guide plates 38a and 38b are provided, after adopting the configuration of FIG. 6 described in the above-described modification (1), as shown in FIG. Guide plates 38a and 38b are provided, and as shown in FIG. 8, it is preferable that the outer cylinder member 36 has a divided structure (divided pieces 36a to 36c). In this case, the inner cylinder member 20 is provided with a guide plate 38a that guides the flow of the coolant toward the radially outer side, while the outer cylinder member 36 (divided pieces 36a to 36c) flows toward the radially inner side. Guidance plates 38b to be guided are respectively provided on the outer cylinder member 36, and the arrangement of the guidance plates 38a and 38b is set so that the guide plates 38a of the inner cylinder member 20 and the guide plates 38b of the outer cylinder member 36 are alternately arranged in the circumferential direction. To do. According to such a configuration, the stator 4 can be assembled by the following procedure. First, adjacent stator cores 22 are connected while making each stator core 22 approach the inner cylinder member 20 from the outside in the radial direction (constituting a stator core connection body), and at the time of this connection, each guide plate 38a of the inner cylinder member 20 is connected. Is inserted between predetermined coils 23 adjacent to each other. Thereafter, the divided pieces 36a to 36c (the outer cylinder member 36) are brought close to and combined with the stator core connection body, and at this time, the guide plates 38b of the divided pieces 36a to 36c are adjacent to each other. Between the two coils 23. And after fixing adjacent division piece 36a-36c with fixing means, such as a volt | bolt, the seal member 24 and the supporting member 26 are assembled | attached to a stator core coupling body. Thus, the stator 4 having a coolant flow path as shown in FIG. 7 is formed.

  If the stator core 22 as shown in FIG. 9 is used, the stator 4 can be configured without the outer cylindrical member 36 having the divided structure as described above. That is, in the stator core 22 shown in the figure, of the two flange portions 47 formed on the bobbin 44, the width dimension of the flange portion 47 on one side (the horizontal dimension in the drawing) is the same as that of the flange portion 47 on the other side. It is set shorter than the width dimension. For example, the shorter flange portion 47 is set to a width dimension equivalent to the width dimension of the coil 23. Further, the bobbin 44 is configured to be connectable by fitting flanges 47 having different lengths in the axial direction.

  As shown in FIG. 9, the stator 4 having the stator core 22 shown in FIG. 9 is assembled with respect to the gap formed between the inner cylinder member 20 and the outer cylinder member 36 which are positioned in advance. Are sequentially connected in the circumferential direction while being alternately inserted from different sides in the axial direction. Accordingly, the stator core coupling body is configured while inserting the guide plates 38 a and 38 b provided on the inner cylinder member 20 and the outer cylinder member 36 between the predetermined coils 23 adjacent to each other. Then, by assembling the seal member 24 and the support member 26 to the stator core coupling body or the like, the stator 4 having a coolant flow path as shown in FIG. 7 can be configured. According to this configuration, it is necessary to pay attention to the direction of the stator core 22 when the stator 4 is assembled, but the configuration of the stator 4 can be simplified because the outer cylinder member 36 does not need to be divided.

  (3) As shown to Fig.10 (a), (b), the teeth part 40a of the core main body 40 of the stator core 22 is formed by the level | step-difference part (side surface of each laminated body g1-g6) formed in the side surface. The step may be filled with a filling member made of a resin material. In FIG. 10A, for the sake of convenience, the portion where the step is filled with resin is indicated by hatching.

  According to such a configuration, since flat surfaces are formed on both sides of the tooth portion 40a and the step portion is apparently eliminated, the contours of the window portion 34 of the support member 26 and the window portion 24b of the seal member 24 are also stepped. Therefore, it is possible to suppress the occurrence of processing defects in the window portions 24b and 34. Therefore, for example, it is possible to suppress the occurrence of trouble such that the seal member 24 and the support member 26 cannot be assembled to the stator core coupling body due to the defective shape of the window portions 24b and 34 (stepped portions). The filling member may be a separate body from the bobbin 44. However, if the mold is designed in advance so that the stepped portions of the laminates g1 to g6 are filled with resin at the time of the insert molding of the stator core 22, the insert It can be molded integrally with the bobbin 44 by molding.

(Second Embodiment)
Next, a rotating electrical machine according to a second embodiment of the present invention will be described. In the following description, portions common to the first embodiment are denoted by the same reference numerals, description thereof is omitted, and differences from the rotating electrical machine 1A of the first embodiment are mainly described.

  FIG. 11 is an exploded perspective view of the rotating electrical machine according to the second embodiment. In the first embodiment, in the rotating electrical machine 1A, the rotor 2 includes two rotor main bodies 12A and 12B, and the stator 4 is interposed between the rotor main bodies 12A and 12B. Although the rotating electrical machine 1B of the second embodiment is an electric machine, the stator 4A, 4B (the first stator 4A, the second stator 4B and the stator 4B) are provided on both sides of one rotor body 12 of the rotor 2, as shown in FIG. 1 rotor and 2 stator type axial gap type rotating electrical machines. Therefore, for the rotor 2, permanent magnets 16 are provided on both surfaces of the rotor body 12 (rotor disk 14).

  As shown in FIGS. 12 and 13, the first stator 4A has an inner cylinder member 20 and an outer cylinder member 36, as in the rotating electrical machine 1A shown in FIG. 6 of the first embodiment. Is provided with a stator core coupling body (stator core 22).

  A support member 26 is fixed via a seal member 24 on one side of the stator core coupling body (stator core 22) or the like, specifically on the rotor body 12 side. This is the same as in the first embodiment, but in the second embodiment, the back yoke 29 is fixed to the other side of the stator core coupling body and the like, and the base member 50 is fixed to the outside thereof.

  The back yoke 29 is formed by laminating and integrating a plurality of electromagnetic steel plates pressed into a disk shape. The back yoke 29 is formed with a shaft hole 29a of the rotary shaft 10 at the center thereof, and a plurality of core insertion portions 29b arranged at equal intervals around the shaft hole 29a. The back yoke 29 is overlaid on the stator core coupling body and the like with the teeth 40a of the core body 40 fitted in each core insertion portion 29b. In this state, the back yoke 29 is bolted to the inner cylinder member 20 and the outer cylinder member 36. It is fixed with B.

  The base member 50 is a disk-shaped member made of a nonmagnetic material such as stainless steel, and is fixed to the back yoke 29 with a bolt (not shown). The base member 50 also serves as an end cover of the housing 6, and a shaft hole 50 a of the rotating shaft 10 is formed at the center. Therefore, in 2nd Embodiment, the housing 6 is comprised only with the cylindrical housing 7, and the end cover 8 for exclusive use is not provided.

  As shown in FIG. 13, the first stator 4 </ b> A is fitted inside the cylindrical housing 7 from one side thereof, and the outer cylinder member 36 is fixed to the cylindrical housing 7 with a bolt B, whereby the cylindrical housing 7. It is assembled to. As shown in the figure, the outer diameter of the base member 50 is set so as to contact the end surface of the cylindrical housing 7. Thereby, the first stator 4A is positioned in the axial direction with respect to the cylindrical housing 7, and the opening of the cylindrical housing 7 is closed.

  As shown in FIG. 13, the first stator 4A has a small diameter of the cylindrical housing 7 as shown in FIG. 14, instead of the outer cylinder member 36 being fixed to the cylindrical housing 7 with bolts B. You may make it fix with the volt | bolt B to the part 7a.

  Although the first stator 4A has been described here, the second stator 4B has the same configuration. Although not shown, the second stator 4B is fitted into the cylindrical housing 7 from the other side (the side opposite to the first stator 4A) and fixed to the cylindrical housing 7 in the same manner as the first stator 4A. Has been.

  The rotor 2 is arranged such that the rotor body 12 is interposed between the stators 4A, 4B assembled to the housing 6. The rotating shaft 10 passes through the centers of the stators 4A and 4B and is inserted into the bearings 28 of the respective support members 26 to be prevented from coming off. Thereby, the rotor 2 is rotatably supported by the stators 4A and 4B.

  Also in the rotary electric machine 1B of the second embodiment as described above, the stator core 22 constituting the stator 4 is the same as that of the first embodiment. Therefore, also in the rotary electric machine 1B of the second embodiment, the same operational effects as those of the rotary electric machine 1A of the first embodiment described above can be enjoyed.

  Also in the rotating electrical machine 1B of the second embodiment, as shown in FIG. 14, a small diameter portion 7a may be provided inside the cylindrical housing 7, and the first stator 4A may be fixed to the small diameter portion 7a. . Specifically, the first stator 4A is obtained by sandwiching the small diameter portion 7a of the cylindrical housing 7 between the support member 26 and the back yoke 29, and fixing the support member 26 and the back yoke 29 to the small diameter portion 7a with a bolt B in this state. May be assembled to the cylindrical housing 7. In this case, the outer cylinder member 36 of the first stator 4A is not necessary. The same applies to the stator 4B.

  In addition, as shown in FIGS. 12 and 13, the back yoke 29 is replaced with one in which a plurality of electromagnetic steel plates pressed in a disk shape are laminated and integrated, as shown in FIGS. 15 (a) and 15 (b). Alternatively, a magnetic steel sheet wound in a spiral shape may be applied, and this may be bonded and fixed to the first stator 4A with a non-conductive adhesive 29c. According to this configuration, the magnetic flux flow can be made smooth without providing a gap between the electromagnetic steel sheets in the magnetic flux flow direction.

  Moreover, although illustration is abbreviate | omitted, about the rotary electric machine 1B of this 2nd Embodiment, the structure of FIGS. 7-10 etc. which were demonstrated in the modification of 1st Embodiment is employable.

  As mentioned above, although embodiment of this invention was described, rotary electric machine 1A, 1B which concerns on 1st, 2nd embodiment mentioned above is a type | mold rotary electric machine (rotary electric machine to which the stator core of this invention was applied) which concerns on this invention. The specific configuration of the stator core and the rotating electrical machines 1A and 1B can be appropriately changed without departing from the gist of the present invention.

  Further, in the first and second embodiments, the example in which the present invention is applied to the axial gap type rotating electric machine has been described. However, the present invention is a so-called configuration in which the rotor and the stator face each other in a direction orthogonal to the rotation axis. It can also be applied to a radial gap type rotating electrical machine.

  That is, although illustration is omitted, as a modification of the rotating electrical machine of the second embodiment, the rotor includes a rotor and a stator disposed on the outer periphery of the rotor, and the rotor is arranged inside the plurality of stator cores arranged in the circumferential direction. Thus, it is possible to configure a radial gap type rotating electrical machine that rotates around a rotation shaft positioned at the center thereof. In this case, the end surface on the rotation axis center side of the stator core is formed in a concave arcuate surface (arc part above the drawing in FIG. 10A) as shown in FIG. An end surface on the shaft side is formed into a convex arc surface having a larger radius of curvature of the arc surface (an arc portion below the drawing in FIG. 10A) via the back yoke portion, and the core body is rotated. A radial gap type rotating electrical machine can be configured by mounting so as to be orthogonal to each other.

DESCRIPTION OF SYMBOLS 1A, 1B Rotating electrical machinery 2 Rotor 4, 4A, 4B Stator 6 Housing 7 Cylindrical housing 10 Rotating shaft 12, 12A, 12B Rotor main body 22 Stator core 23 Coil 26 Support member 41 Electrical steel sheet 44 Bobbin 46 Cylindrical part 47 Gutter part

Claims (2)

A stator core of a rotating electric machine,
A core body formed by laminating a plurality of steel plates of a predetermined shape;
A bobbin formed of an insulative resin material, surrounding the core body in a state in which the end of the core body in a direction orthogonal to the stacking direction of the steel plates is exposed, and a coil is wound outside. Including,
The core body is configured by laminating a plurality of laminated bodies each having a plurality of steel plates having the same shape laminated in the laminating direction,
Each laminated body has different dimensions in the width direction perpendicular to the laminating direction, and the laminated body located on the other side has a larger dimension in the width direction than the laminated body located on one side in the laminating direction. Is set,
And the core body and the bobbin are integrally molded by insert molding,
The end of the core body protrudes outward from the bobbin,
A stator core , wherein a flat surface is formed on both sides in the width direction of the end portion by filling a stepped portion of the laminated body at the end portion with a filling member made of a resin material . It is a manufacturing method of the stator core according to claim 1 ,
A preparatory step of preparing a plurality of steel plates each having a predetermined shape and each having a notch for positioning at a predetermined position on the outer peripheral portion;
The plurality of steel plates are aligned and laminated so that the notches are arranged in a row, and the insert molding is performed by storing the laminated steel plates in a mold in a state of being positioned using the notches. And a forming step of forming the bobbin around the plurality of steel plates. A method for manufacturing a stator core, comprising:

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