JP6248566B2 - Stator core of rotating electrical machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a laminated core type stator core suitable for a stator core of a rotating electrical machine, in particular, a stator of an automotive alternator, and a method for manufacturing the same.

[Conventional technology]
Conventionally, various types of laminated core type stator cores have been put to practical use. However, in recent years, a ring-shaped plate having teeth and slots on the inner peripheral side from a magnetic plate (for example, a steel plate). Instead of a laminated core formed by laminating a large number of ring-shaped plates in a cylindrical shape, a strip-shaped core with a tooth portion and a slot portion formed on one side for the reason that there is little waste material and the material yield is good A so-called wound iron core, which is formed by winding a sheet in a spiral shape (helical) and winding and laminating a plurality of layers in a cylindrical shape, has been exclusively employed (for example, see Patent Document 1).

Furthermore, in this type of wound core, as an additional functional configuration, for example, the outer peripheral side of the core sheet of each layer is formed in a taper shape so that it can be easily wound when being bent into an annular shape. In order to compress and fix the laminated core from the axial direction, a fixing notch is provided on the outer peripheral surface of the laminated core over the entire length in the axial direction.
As shown in FIG. 9, a stator coil C using, for example, a flat wire (rectangular cross-section conductor) as the element wire C <b> 1 is housed (wound) in the slot portion 12. In the following description, the strand C1 is also referred to as a conductor C1.

  By the way, in the rotating electrical machine where the restrictions on mounting are severe like the AC generator for automobiles, further downsizing and higher performance are expected year by year. Especially, the problem on the stator side is how to deal with the stator core. A common proposition for those skilled in the art is to increase the space factor of the stator coil by winding the stator coil as densely as possible.

[Problems of the prior art]
The present inventor has conducted numerous experiments and researches aiming at further improvement of the space factor of the stator coil, but this time, after examining the storage (winding) state of the stator coil, I found out that such problems were inherent.
(1) For example, a rectangular wire adopted as a strand (conductor) of a stator coil has a rectangular cross section and can be closely overlapped, so that a high space factor can be expected. Although it has been used, a dead space that cannot be ignored is confirmed between the lowermost conductor of the stator coil and the bottom surface of the slot.
That is, as shown in FIG. 9, each slot portion 12 of the laminated core 1 (stator core D) has a U-shape as a whole, but the bottom surface 12a of the slot portion 12 and the side surface 11a of the tooth portion 11 are formed. Since the corner portion 12X to be connected exists, the dead space 12Y is generated when the corner portion 12X interferes with a part of the stator coil C (conductor C1).
(2) Further, the interference causes an event in which the lowermost conductor C1 of the stator coil C and the corner portion 12X of the slot portion 12 are rubbed locally, and the insulating coil of the conductor C1 is damaged. The reliability of C may be reduced.

Japanese Patent Laid-Open No. 62-244248

  The present invention has been made to solve the above-described problems, and its purpose is to eliminate dead space between the stator coil and the slot portion and local friction of the stator coil, and An object of the present invention is to provide a stator core that can ensure a high space factor and high reliability, and to provide a manufacturing method that can manufacture such a stator core economically and with high quality.

The invention described in 請 Motomeko 1 (stator core of a rotary electric machine) is band-shaped core sheet made of a magnetic plate is used as the core material, the core sheets are laminated in the axial direction while being formed bent annularly Thus, a cylindrical laminated core is formed as a whole, and the core sheet alternately has teeth and slots for winding the stator coil on the inner peripheral side, and on the outer peripheral side. The basic configuration is to have a yoke portion that connects the teeth portion and the slot portion at a predetermined pitch.

In the stator core of the present invention, the core sheet includes a deep groove portion having the following characteristics as a space factor improving means at a boundary portion between the tooth portion and the slot portion.
The deep groove portion penetrates in the plate thickness direction, and has a tapered shape formed so as to be recessed from the bottom surface of the slot portion toward the outer diameter direction and bite into the yoke portion. In addition, in the deep groove portion, the length (width) in the circumferential direction of the opening is made smaller than the thickness of the strand of the stator coil.
Further, the stator coil uses a rectangular wire having a rectangular cross section as an element wire.

  According to the above configuration, since there is no corner that connects the bottom surface of the slot portion and the side surface of the tooth portion, the dead space between the stator coil and the groove bottom surface is eliminated, and the stator coil is placed on the groove bottom surface with respect to the slot portion. And the space factor of the stator coil can be improved (increased).

  Further, since the opening of the deep groove portion has a width in the circumferential direction smaller than the thickness of the strand of the stator coil, the strand of the stator coil does not fit into the deep groove portion, and the above-mentioned Combined with the disappearance of the corners, local interference and friction between the stator coil and the teeth and slots are prevented, and there is no risk of damage to the insulation film of the strands. It can improve (enhance).

The deep groove portion is formed by cutting into only the yoke portion having a relatively large magnetic path area and does not sacrifice the magnetic path area of the tooth portion. The stator core with high magnetic performance can be obtained.
According to the second aspect of the present invention, the deep groove portion is provided on both sides in the circumferential direction of the bottom surface of the slot portion, and a circle from the opening edge of one deep groove portion to the opening edge of the other deep groove portion. The maximum circumferential width V is the same as the circumferential width X of the slot portion.
According to this, since the deep groove portion has no influence on the teeth portion (its magnetic path area), high magnetic performance can be ensured as a stator core.
Further, according to the invention described in claim 3, the yoke portion has a thick portion in which the inner peripheral side to the deepest portion of the deep groove portion has the same plate thickness as the thickness of the teeth portion. The outer peripheral side forms a tapered thin portion where the plate thickness gradually decreases toward the outer diameter direction.
According to this, since the upper and lower entire surfaces of the layers of the core sheet are in close contact with each other by the thick portion of the yoke portion, and the deep groove portion does not interfere with the tapered thin portion, the gap between the thin portions is interposed via the deep groove portion. S is not connected to the inside of the slot portion. Therefore, it is possible to prevent water (leakage) from entering the laminated core.

[Means of claim 6]
According to the invention described in claim 6 (method for manufacturing a stator core of a rotating electrical machine), in manufacturing the stator core , a belt-shaped core sheet having a teeth portion, a slot portion, and a yoke portion is produced from a magnetic plate. In the process, the core sheet manufacturing step of forming a triangular expansion groove portion where the opening portion is greatly expanded as an intermediate shape of the deep groove portion, positioned at the boundary portion between the teeth portion and the slot portion , In the process of forming the core sheet in an annular shape so that the yoke part is on the outer peripheral side, winding is performed to form a desired triangular deep groove part while narrowing the opening part of the expanding groove part from the circumferential direction. And a process.

  According to the manufacturing method described above, since a desired deep groove portion can be easily formed without requiring a special processing step for the deep groove portion, it is economical. Further, in the process of narrowing the widening groove portion and forming the deep groove portion, the compressive strain around the slot portion can be absorbed, so that the event that the periphery of the slot portion expands in the plate thickness direction is not caused. In the sheet winding process, the sheet can be smoothly bent into an annular shape without affecting the plate thickness. Therefore, since the laminated core can be densely laminated with no gap in the axial direction and each layer can have a cylindrical shape with high roundness, a high-quality stator core can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS In order to explain the basic configuration of a rotating electrical machine having a stator core to which the present invention is applied, (a) is a schematic cross-sectional view of the upper half of an automotive alternator, and (b) is a diagram of a stator core. (Example 1) which is an enlarged plan view of the principal part. It is used for explanation of the basic structure of the laminated core constituting the stator core and the basic process of the method of the present invention, and shows the manufacturing process. (A), (b) are strip cores obtained in the core sheet manufacturing process. A plan view and AA cross-sectional view of the sheet, (c) and (d) are a plan view and BB cross-sectional view of the strip-shaped core sheet obtained in the winding step, and (e) and (f) are side views of the laminated core. FIG. 2 is a cross-sectional view taken along the line CC (Example 1). BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic enlarged view of a main part showing a relationship with a stator coil for explaining a first embodiment of a stator core to which the present invention is applied (Example 1). FIG. 2 is a diagram for explaining a second embodiment of a stator core to which the present invention is applied, wherein (a) is a partially enlarged plan view of a stator core as a comparative example, (b) is a cross-sectional view taken along the line A-A of FIG. ) Is a schematic enlarged plan view of the main part of the stator core in the second embodiment, and (d) is a BB cross-sectional view thereof (Example 2). FIG. 7 is a diagram for explaining a third embodiment of a stator core to which the present invention is applied, in which (a) is a schematic enlarged plan view of a main part of the stator core, and (b) is a cross-sectional view taken along line AA in FIG. Example 3). In the description of the fourth embodiment of the stator core to which the present invention is applied and one embodiment of the method of the present invention, (a) shows the main part of the stator core showing the manufacturing process in the core sheet winding step. A schematic enlarged plan view, (b) is an AA cross-sectional view (Example 4). (A), (b) is the schematic diagram with which it uses for process description in the core sheet winding process in this invention method (Example 4). The stator core of the conventional rotary electric machine is shown, (a) is the elements on larger scale of a stator core, (b) is the AA sectional drawing (prior art). It is the elements on larger scale which show the relationship with the stator coil in the conventional stator iron core (prior art).

  Hereinafter, the best mode for carrying out the present invention will be described in detail according to embodiments shown in the drawings.

Each example shows a stator core of an alternator for automobiles as a representative example of a stator core to which the present invention is applied. In the following description, first, the basic configuration of an alternator for automobiles is shown. The features of each embodiment of the present invention will be described in order, and finally the actions and effects of the features of the present invention will be summarized and listed.
In each embodiment, the same or equivalent parts are denoted by the same reference numerals, and redundant description is omitted.

[Example 1]
The overall configuration of an AC generator G that is a rotating electrical machine to which the present invention is applied will be described with reference to FIGS. 1 and 2.

[Basic configuration of AC generator G]
As shown in FIG. 1 (a), an AC generator G includes a rotor GR attached to a rotating shaft J driven by an engine, and a pair of cup-shaped housings (also referred to as frames) H. And a stator core GS composed of a cylindrical laminated core as an iron core on which a stator coil (multi-phase winding) C is mounted. (Laminated core type stator core, wound core) D is used.
Further, the stator core D is used as a part of the casing of the AC generator G by being sandwiched and fixed by a pair of cup-shaped housings H, and is also exposed to a severe external environment.

[Basic structure of laminated core 1]
As shown in FIG. 1B, the laminated core 1 constituting the stator core D is configured by laminating a core sheet 10 made of a magnetic plate, and a large number of stator coils C are wound on the inner peripheral side. Teeth (teeth) portions 11 and slots (grooves) portions 12 are alternately provided, and yoke (joint) portions 13 that connect the teeth portions 11 and the slot portions 12 annularly at a predetermined pitch are provided on the outer peripheral side. .
The annular yoke portion 13 is a non-winding portion around which the stator coil C is not wound, and a space factor improving means DX described in detail later is constructed at the boundary portion between the tooth portion 11 and the slot portion 12. Yes.
A fixing notch 16 is provided on the outer periphery of the stator core D (laminated core 1) to be used for inserting the assembly bolt B.

As shown in FIG. 2, the laminated core 1 uses a strip-shaped core sheet 10 made of a magnetic plate 100 as an iron core material. This core sheet 10 is produced, for example, as a pair (two sheets) of strip-shaped core sheets by punching out a wide elongated magnetic plate so that the teeth and slots are alternately arranged, Alternatively, it is produced as a single band-shaped core sheet by punching from a narrow band-shaped magnetic plate so that teeth and slots are alternately arranged on one side thereof.
Thus, as shown in FIGS. 2A and 2B, the strip-shaped core sheet 10 includes teeth (tooth) portions 11 and slots (grooves) for winding the stator coil C on one side in the length direction. ) Portion 12 and a yoke (joint) portion 13 for connecting the teeth portion 11 and the slot portion 12 at a predetermined pitch on the other side in the length direction. The space factor improving means DX is provided in the boundary region between the tooth portion 11 and the slot portion 12.
Then, as shown in FIGS. 2C and 2D, the core sheet 10 is formed in an axial direction while being bent in an annular shape so that the yoke portion 13 is on the outer peripheral side (while being spirally wound). By winding and laminating over a plurality of layers, a cylindrical laminated core 1 is obtained as shown in FIGS.

  As shown in FIGS. 2D and 2F, the yoke portion 13 of the core sheet 10 forms a thick portion 14 having the same thickness as that of the teeth portion 11 on the inner peripheral side. The outer peripheral side of the thick portion 14 forms a tapered thin portion 15 in which the plate thickness gradually decreases toward the outer diameter direction. The thin portion 15 is formed by plastic deformation in the “process of winding the laminated core 1 into a cylindrical shape”, and increases the substantial winding circumference on the outer peripheral side of the laminated core 1. The core sheet 10 has a function of easily winding up the core sheet 10 in a spiral shape.

  Here, “the process of forming the laminated core 1 in a cylindrical shape” means a process from the stage before the core sheet 10 is spirally wound (pre-process) until the core sheet 10 is further wound. As a specific method for forming the thin portion 15 in the process, there are the following two methods. In the first method, when the core sheet 10 is wound in a spiral shape, for example, a rolling part is provided on a winding roller that sandwiches the core sheet 10, and the thin part 15 is formed and simultaneously wound in a spiral shape. In the second method, at the stage of the strip-shaped core sheet 10 shown in FIG. 2A, as a pre-process for winding the core sheet 10 in a spiral shape, the thin portion 15 is formed by rolling, for example, by pressing. It is a method to do.

  The laminated core 1 is one in which the layers are fixed to each other by appropriate fixing means in the stacking direction (axial direction). In order to load a wedge as the fixing means (see Patent Document 1), A fixing notch 16 is provided in the outer peripheral surface of the laminated core 1 in the axial direction for use in inserting the assembly bolt B (see FIG. 1A).

[Features of laminated core 1]
The feature of the present invention is that the space factor improving means DX is constructed at the boundary portion between the tooth portion 11 and the slot portion 12 in the yoke portion 13 of the laminated core 1.
In this embodiment, a deep groove portion 17 having a structure as shown in FIG. 3 is provided as the space factor improving means DX.

In FIG. 3, the deep groove portion 17 has the following characteristics.
(1) In the core sheet 10, the deep groove portion 17 is recessed toward the outer diameter direction from the bottom surface 12 a of the slot portion 12 at the boundary portion between the tooth portion 11 and the slot portion 12, and bites into the yoke portion 13. Is formed.
(2) The deep groove portion 17 penetrates in the plate thickness direction, and has a tapered shape in which the radial length (depth) is larger than the circumferential length (width W) of the opening 17a. Yes. More specifically, one side of the deep groove portion 17 obliquely bites into the yoke portion 13 from the bottom surface 12a of the slot portion 12, and the other side is straight from the side surface 11a of the teeth portion 11 (side surface 12b of the slot portion 12) in the radial direction. It is connected and has a substantially right triangle shape. This triangular (tapered) vertex is referred to as the deepest portion 17b.
(3) The deep groove portions 17 are formed between all the tooth portions 11 and the slot portions 12, and are therefore attached to both sides in the circumferential direction of the bottom surface 12 a with respect to each slot portion 12.
(4) The pair of deep groove portions 17 located on both sides in the circumferential direction of each slot portion 12 has a circumferential maximum width V from the opening edge of one deep groove portion 17 to the opening edge of the other deep groove portion 17. Is the same as the circumferential width X of the slot portion 12. Therefore, the deep groove portion 17 has no influence on the tooth portion 11 (its magnetic path area).
(5) Further, in each deep groove portion 17, the width W (the length in the circumferential direction) of the opening portion 17a is made smaller than the thickness Y of the strand C1 of the stator coil C.
In the present embodiment, the stator coil C is a rectangular wire (thick wire) having a rectangular cross section as the strand C1, and the thickness Y of the strand C1 is considerably thick, but the wire diameter of the strand C1 is as follows. The one using a round wire (thin wire) having a thin cross-section is also in practical use. In the present invention, even in such a case, the opening width W of the deep groove portion 17 is set smaller than the diameter of each round wire. Therefore, the strand C1 of the stator coil C does not fit into the deep groove portion 17.

[Effect of Example 1]
According to the above configuration, the corner portion (shown in FIG. 9) connecting the bottom surface 12a of the slot portion 12 and the side surface 11a of the tooth portion 11 (side surface 12b of the slot portion 12) at the boundary portion between the tooth portion 11 and the slot portion 12. Since the corner portion 12X) is eliminated, the stator coil C can be fully accommodated in the slot portion 12 up to the groove bottom surface 12a.
Thus, it is possible to prevent a dead space 12Y as shown in FIG. 9 from being generated between the stator coil C and the bottom surface 12a of the slot portion 12, and to increase (improve) the space factor of the stator coil C accordingly. .

  Further, since the width 17 of the opening 17a of the deep groove portion 17 is smaller than the thickness of the strand C1 of the stator coil C, the strand C1 of the stator coil C may be fitted into the deep groove portion 17. In combination with the absence of the corners, local interference and friction between the stator coil C, the teeth portion 11 and the slot portion 12 can be prevented. Therefore, the insulating coating of the stator coil C (element wire C1) is not damaged, and the reliability of the stator coil C is improved.

[Example 2]
Next, a second embodiment of the stator core D to which the present invention is applied will be described with reference to FIG.
As is clear also in the first embodiment, the laminated core 1 has a gap S (see FIG. 2F) due to the tapered thin portion 15 on the outer peripheral surface. Moreover, since the laminated core 1 is used as a part of the casing of the AC generator G and is exposed to a severe external environment, a situation where the outer peripheral surface is flooded cannot be avoided.

  Therefore, as in the comparative example shown in FIGS. 4A and 4B, in the yoke portion 13 of the core sheet 10, the radial width of the tapered thin portion 15 is substantially the same as the radial width of the yoke portion 13 ( If the large groove portion 17 is formed so as to substantially eliminate the thick wall portion 14), the deep groove portion 17 interferes with the tapered thin wall portion 15, so that the gap S is connected to the inside of the slot portion 12 through the deep groove portion 17. Inundation (leakage) into 1 is a concern.

  The present embodiment was devised to solve such a problem. As shown in FIGS. 4C and 4D, the yoke portion 13 of the core sheet 10 extends to the deepest portion 17 b of the deep groove portion 17. The inner peripheral side forms a thick portion 14 having the same thickness as the tooth portion 11 over the entire circumference, and the plate thickness gradually decreases as the outer peripheral side of the thick portion 14 extends in the outer diameter direction over the entire circumference. A tapered thin-walled portion 15 is formed. Therefore, the thick portion 14 having a constant width Z is provided in the radial direction on the inner peripheral side of the yoke portion 13.

According to the above configuration, each layer of the core sheet 10 is in close contact with the upper and lower surfaces by the thick portion 14 of the yoke portion 13, and does not interfere with the tapered thin portion 15 until the deep groove portion 17 reaches the deepest portion 17b. The gap S is not connected to the inside of the slot portion 12 through the deep groove portion 17. Therefore, water immersion (leakage) into the laminated core 1 can be prevented in advance.
Thus, when water is leaked into the laminated core 1 (leakage), for example, corrosion of the stator coil C may be induced. However, such a concern may be eliminated and the reliability of the stator coil C may be improved. it can.

[Example 3]
Next, a third embodiment of a stator core D to which the present invention is applied will be described with reference to FIG.
As is clear also in the first embodiment, the laminated core 1 has a basic configuration in which the layers are fixed to each other by appropriate fixing means in the stacking direction (axial direction). However, in order to load a wedge as the fixing means. Alternatively, there is provided a stator core D of a type in which a fixing notch 16 provided for inserting the assembly bolt B (see FIG. 1A) is provided on the outer peripheral surface of the laminated core 1 in the axial direction. is there.
The present embodiment shows one specific example suitable as a stator core D of the type having such a fixing notch 16.

As shown in FIG. 5A, the yoke portion 13 of the core sheet 10 is provided with a thick portion 14 on the inner peripheral side and a tapered thin portion 15 on the outer peripheral side. The thin portion 15 is defined by a boundary line 13X.
The fixing notch 16 has a semicircular recess recessed from the outer peripheral surface toward the inner diameter direction in the yoke portion 13, and its bottom surface 16 a is near the boundary line 13 </ b> X between the thick portion 14 and the thin portion 15 ( It is located on the boundary line 13X or on its inner diameter side. In particular, in this embodiment, the bottom surface 16a of the fixing notch 16 is provided so as to bite into the inner diameter side of the boundary line 13X, that is, the thick portion 14.

According to the above configuration, the plate thickness in the vicinity of the bottom surface 16a of the fixing notch 16 is the thick portion 14 and is not a tensile deformation region in which the plate thickness decreases like the thin portion 15, and thus the stator core D It is possible to suppress a decrease in rigidity.
In addition, by making the boundary line 13X coincide with a neutral line (neutral line 10X) to be described later, the bottom surface 16a of the fixing notch 16 is positioned on the inner diameter side including the boundary line 13X. Since the bottom surface 16a of the notch 16 is present in the compression-side deformation region, a decrease in the rigidity of the stator core D can be suppressed.

[Example 4]
Next, a fourth embodiment of a stator core D to which the present invention is applied and an embodiment of the method of the present invention will be described with reference to FIGS.

Also in the present example, for example, a structure and a manufacturing method in which the core sheet manufacturing process and the winding process as shown in FIG.
That is, as a basic process, as shown in FIGS. 2 (a) and 2 (b), a belt-like shape having a tooth portion 11, a slot portion 12, a yoke portion 13 and a space factor improving means DX (deep groove portion 17) from the magnetic plate 100 2A and 2D and FIG. 2C and FIG. 2D, the yoke portion 13 of the core sheet 10 becomes the outer peripheral side while forming the tapered thin portion 15 as shown in FIGS. And a winding step of forming an annular shape.

  In particular, the present embodiment is provided for supplementary explanation of the features of the present invention on both the structural surface and the method surface. (1) On the structural surface, the plastic deformation mechanism of the stator core D in each of the embodiments described above is provided. Embodiments that have been compiled in consideration are shown, and (2) in terms of the method, an embodiment in which the above-described stator core D can be manufactured economically and with high quality is shown.

[Structural features]
First, the structural features will be described. The feature of this embodiment is that the arrangement of the deep groove portions 17 is set in a special relationship as follows in consideration of the plastic deformation phenomenon of the core sheet 10 that occurs in the winding process. There is in point.

That is, considering the plastic deformation phenomenon of the core sheet 10, in the winding process, the core sheet 10 is generally plastically deformed according to a deformation model as shown in FIG. In FIG. 7, the core sheet 10 is bent from the straight state shown in FIG. 7A by applying a bending deformation moment M as indicated by an arrow, and as shown in FIG. A plastic deformation phenomenon occurs, and a plastic deformation phenomenon that tries to compress on the inner peripheral side occurs.
As described above, when the regions of the plastic deformation phenomenon occurring on the inner peripheral side and the outer peripheral side of the core sheet 10 are referred to as the compression side deformation region and the tension side deformation region, respectively, they form a boundary between these two regions and do not compress or stretch. An area exists. This region is a portion indicated by a one-dot chain line, and this is called a neutral line 10X.
In this embodiment, as shown in FIG. 6, the deepest portion 17b of the deep groove portion 17 is set to be positioned near the neutral line 10X (on the neutral line 10X or on the inner diameter side from the neutral line 10X). Features.

Conventionally, the core sheet 10 is not provided with any space factor improving means DX as in the present invention, and an event as shown in FIG. 8 occurs in the winding process.
That is, in FIG. 8, the core sheet 10 has a slot portion 12 in an expanded state as shown by a broken line as shown in FIG. 8A, and this is narrowed as shown by a solid line in the winding process. At this time, as described above, compression deformation occurs on the inner peripheral side from the neutral line 10X, so that the plate thickness near the bottom of the slot portion 12 expands as shown in FIG. 8B.
Due to the expansion of the plate thickness, the core sheets 10 cannot be densely stacked, which causes various problems such as a decrease in magnetic performance and occurrence of water leakage.
On the other hand, in the present embodiment, as shown in FIG. 6, on both sides in the circumferential direction of the slot portion 12, the deep groove portion 17 has its deepest portion 17b in the vicinity of the neutral line 10X (on the line of the neutral line 10X or its inner diameter). (Side).

[Effects in structure]
According to the above configuration, in the winding process of the core sheet 10, as shown in FIG. 6A, the groove width of the deep groove portion 17 is circular even if the slot portion 12 is narrowed from the expanded state of the broken line as shown by the solid line. Only the reduction in the circumferential direction does not affect the plate thickness (see FIG. 6B).
That is, the deep groove portion 17 has the entire depth region from the opening portion 17 a to the deepest portion 17 b located in the compression side deformation region of the core sheet 10. By utilizing this as a relief region for compressive deformation in the direction and reducing the depth of the deep groove portion 17 in the width direction, the entire distortion can be offset (absorbed). Therefore, since the material itself does not undergo compressive strain, the core sheet 10 can be prevented from expanding in the thickness direction.
Thus, in the core sheet 10 winding step, the core sheet 10 can be densely wound and laminated, and a high-quality laminated core 1 can be obtained.

[Method features]
Next, features in terms of methods will be described.
In the present embodiment, as described above, as shown in FIG. 2A, as a basic process, as shown in FIG. 2 (a), a belt-like shape having the teeth portion 11, the slot portion 12, the yoke portion 13 and the space factor improving means DX from the magnetic plate 100 is used. As shown in FIG. 2B, the core sheet 10 is formed in an annular shape so that the yoke portion 13 is on the outer peripheral side while forming the tapered thin portion 15 as shown in FIG. A winding step for forming a song.
In the method aspect of the present embodiment, as the space factor improving means DX, in providing the deep groove portion 17 as in each of the embodiments described above, (1) First, in the core sheet manufacturing step, FIG. As shown by a broken line, an expanded groove portion 17X having an opening that is greatly expanded is formed as an intermediate shape of the deep groove portion 17, and (2) in the subsequent winding step, the core sheet 10 is replaced by the yoke portion 13 In the process of forming an annular shape so as to be on the outer peripheral side, a desired deep groove portion 17 is formed as shown by a solid line while narrowing the opening portion of the expanded groove portion 17X.

[Method effects]
According to the method of the present invention, the expanded groove portion 17X that forms the intermediate shape of the deep groove portion 17 has a simple V-shape that can be provided in any size, and the teeth portion is formed when the core sheet 10 is manufactured. 11 and the slot portion 12 can be easily and simultaneously punched, and therefore, a special process for providing the expanded groove portion 17X and hence the deep groove portion 17 is not required.
Further, in the winding process of the core sheet 10, the core sheet 10 is formed in an annular shape (winding) while narrowing the groove width of the expanded groove portion 17 </ b> X, that is, eliminating the compressive strain. A desired roundness can be ensured in the layer, and the laminated core 1 having a high roundness can be obtained.
Thus, the stator core D capable of realizing the high space factor and high reliability of the stator coil C described above can be manufactured economically and with high quality.

[Modification]
Although the present invention has been described in detail with respect to the four embodiments, various modifications can be made without departing from the spirit of the present invention, and modifications thereof will be exemplified.

(1) In each example, the core sheet 10 is provided with the tapered thin portion 15 whose upper and lower surfaces are tapered over the entire circumference as the thin portion 15 on the outer peripheral side, but only one of the upper and lower sides is provided. It is good also as a single-sided taper-shaped thin part made into a taper surface.
However, considering the specifications on the product side, for example, the diameter (curvature) of the laminated core 1, the radial width of the core sheet 10, and the conditions on the manufacturing side, for example, bending means, the same plate thickness The space factor of the stator coil C can be improved by applying the deep groove portion 17 as the space factor improving means DX to the stator core D that is bent in an annular shape (without providing the thin portion 15). Of course.

(2) In each embodiment, the deep groove portions 17 are provided on both sides of the slot portion 12 in the circumferential direction. However, the deep groove portions 17 are provided only on one side of the slot portion 12 according to the degree of absorption of the compressive strain. May be provided.
(3) Further, the shape of the deep groove portion 17 is not limited to a triangular shape, and the dimensional relationship between the depth and the width W is not limited to the relationship as in the embodiment (depth> width W). Tapered shape can be adopted. Since the deep groove portion 17 has an incidental function of absorbing compressive strain, it is important that the bottom surface of the deepest portion 17b is as small as possible (in order to prevent large compressive strain). Thus, the form from the opening 17a to the deepest part 17b can be freely selected.
If the production surface (processed surface) is taken into consideration, the bottom surface shape of the deepest portion 17b of the deep groove portion 17 is not an acute angle surface but a so-called R surface such as a circle, or the bottom surface of the deepest portion 17b is used for die cutting. Circular holes may be connected.
(4) Further, the deep groove portion 17 can make the width W of the opening portion 17a as small as possible without sacrificing the incidental function, and the final shape has a slight gap that is not in close contact. It ’s fine. Incidentally, in the case of the stator core D having an outer diameter of 130 mm and an inner diameter of 100 mm, the width W is about 0.35 to 0.50 mm, and the depth is about 1.0 to 1.5 mm.

(5) In the above embodiment, the case where the present invention is applied to a stator core of an automotive alternator (alternator) has been described. However, the present invention is not limited to this, and a laminated core type made of a magnetic plate is used as the core material. The present invention can be applied to a rotating electric machine having a stator core, for example, a high voltage drive motor, and achieve the same effects.

  The features and advantages of the present invention that have been described in detail above will be summarized as follows according to each means described as a dependent claim (excluding dependent claim 6) in the claims.

(Feature 1 = Means of claim 2)
In the stator iron core D of the rotating electrical machine according to claim 1,
The deep groove portions 17 are attached to both sides in the circumferential direction of the bottom surface 12a of the slot portion 12. The maximum circumferential width V from the opening edge of one deep groove portion 17 to the opening edge of the other deep groove portion 17 is: It is characterized by being the same as the circumferential width X of the slot portion 12 (Examples 1 to 4).
According to the above means, the deep groove portion 17 has no influence on the tooth portion 11 (its magnetic path area), and thus high magnetic performance can be secured as the stator core D.

(Feature point 2 = Means of claim 3)
In the stator iron core D of the rotating electrical machine according to claim 1 or 2,
The yoke portion 13 has an inner peripheral side up to the deepest portion 17b of the deep groove portion 17 forming a thick portion 14 having the same thickness as the thickness of the tooth portion 11, and an outer peripheral side of the thick portion 14 is in the outer diameter direction. A taper-shaped thin portion 15 is formed in which the plate thickness gradually decreases toward () (Examples 1 to 4).
According to the above means, each layer of the core sheet 10 is in close contact with the upper and lower surfaces by the thick portion 14 of the yoke portion 13 and the deep groove portion 17 does not interfere with the tapered thin portion 15 at all. Thus, the gap S is not connected to the inside of the slot portion 12. Therefore, water immersion (leakage) into the laminated core 1 can be prevented.

(Feature point 3 = Means of claim 4)
In the stator iron core D of the rotating electrical machine according to claim 3,
The yoke portion 13 includes a fixing notch 16 that is recessed from the outer peripheral surface toward the inner diameter direction, and the bottom surface 16 a of the fixing notch 16 is located near the boundary line between the thick portion 14 and the thin portion 15. (Example 3).
According to the above means, the plate thickness in the vicinity of the bottom surface 16 a of the fixing notch 16 is the thick portion 14, and is not a tensile deformation region in which the plate thickness decreases like the thin portion 15. Reduces rigidity.

(Feature point 4 = Means of claim 5)
In the stator iron core D of the rotating electrical machine according to any one of claims 1 to 4,
The regions of the plastic deformation phenomenon that occur on the inner peripheral side and the outer peripheral side of the core sheet 10 when the core sheet 10 is bent into an annular shape are called a compression side deformation region and a tension side deformation region, respectively. When we call the neutral line 10X the area that does not bound or compress or stretch,
The deepest portion 17b of the deep groove portion 17 is located on the inner diameter side including the neutral line 10X (Examples 3 and 4).
According to the above means, since the deep groove portion 17 functions as an incidental function of absorbing compressive strain, the core sheet 10 can be prevented from expanding in the plate thickness direction, and the core sheet 10 is tightly wound / laminated. Thus, a high-quality laminated core 1 (stator core D) can be obtained.

(Feature point 5 = Means of claim 6)
A method of manufacturing a stator core D of a rotating electrical machine according to any one of claims 1 to 5, wherein the intermediate shape of the magnetic plate 100 to the tooth portion 11, the slot portion 12, the yoke portion 13 and the deep groove portion 17 is provided. A core sheet manufacturing step of manufacturing the strip-shaped core sheet 10 having the expanded groove portion 17X forming
A winding step of forming the deep groove portion 17 while narrowing the opening portion of the expanded groove portion 17X in the process of forming the core sheet 10 in an annular shape so that the yoke portion 13 is on the outer peripheral side. It is characterized (Example 4).
According to the above means, since the widened groove portion 17X having an intermediate shape of the deep groove portion 17 can be easily and simultaneously punched together with the teeth portion 11 and the slot portion 12 when the core sheet 10 is manufactured, the widened groove portion 17X. Therefore, a special process for providing the deep groove portion 17 is not required. Further, in the winding process of the core sheet 10, the core sheet 10 is formed in an annular shape (winding) while narrowing the groove width of the expanded groove portion 17 </ b> X, that is, eliminating the compressive strain. A desired roundness can be ensured in the layer, and the laminated core 1 having a high roundness can be obtained.
Therefore, the stator core D that can obtain the high space factor and high reliability of the stator coil C described above can be manufactured economically and with high quality.

DESCRIPTION OF SYMBOLS 1 ... Laminated core, 10 ... Core sheet, 11 ... Teeth part, 12 ... Slot part, 12a ... Bottom face, 13 ... Yoke part, 17 ... Deep groove part, 17a ... Opening part, 100 ... Magnetic board, G ... AC power generation for motor vehicles Machine (rotary electric machine), C: stator coil, C1: strand, D: stator core, W: width.

Claims (9)

A belt-shaped core sheet (10) made of a magnetic plate (100) is used as an iron core material, and the core sheet (10) is formed in an annular shape and laminated in the axial direction, thereby forming a cylindrical shape as a whole. The laminated core (1) is configured,
The core sheet (10) alternately has teeth (11) and slots (12) for winding the stator coil (C) on the inner peripheral side, and the teeth (11) on the outer peripheral side. In the stator core (D) of the rotating electrical machine (G) having a yoke portion (13) that connects the slot portions (12) at a predetermined pitch,
The core sheet (10) has a deep groove portion (17) at a boundary portion between the teeth portion (11) and the slot portion (12).
The deep groove portion (17) penetrates in the thickness direction of the core sheet (10), and is recessed in a tapered shape from the bottom surface (12a) of the slot portion (12) toward the outer diameter direction. It has a triangular shape that bites into (13), and
The deep groove portion (17) has a circumferential length (width W) of an opening portion (17a) opening toward the inner diameter direction on the bottom surface (12a) side of the strand of the stator coil (C). It is smaller than the thickness (C1) ,
The stator coil (C) is a stator core (D) of a rotating electrical machine (G), wherein a rectangular wire having a rectangular cross section is used as an element wire . A belt-shaped core sheet (10) made of a magnetic plate (100) is used as an iron core material, and the core sheet (10) is formed in an annular shape and laminated in the axial direction, thereby forming a cylindrical shape as a whole. The laminated core (1) is configured,
The core sheet (10) alternately has teeth (11) and slots (12) for winding the stator coil (C) on the inner peripheral side, and the teeth (11) on the outer peripheral side. In the stator core (D) of the rotating electrical machine (G) having a yoke portion (13) that connects the slot portions (12) at a predetermined pitch,
The core sheet (10) has a deep groove portion (17) at a boundary portion between the teeth portion (11) and the slot portion (12).
The deep groove portion (17) penetrates in the thickness direction of the core sheet (10), and is recessed in a tapered shape from the bottom surface (12a) of the slot portion (12) toward the outer diameter direction. It has a triangular shape that bites into (13), and
The deep groove portion (17) has a circumferential length (width W) of an opening portion (17a) opening toward the inner diameter direction on the bottom surface (12a) side of the strand of the stator coil (C). It is smaller than the thickness (C1),
Furthermore, the deep groove portion (17) is attached to both sides in the circumferential direction of the bottom surface (12a) of the slot portion (12),
The maximum circumferential width from the opening edge of one of the deep groove portions (17) to the opening edge of the other deep groove portion (17) is the same as the circumferential width of the slot portion (12). A stator core (D) of a rotating electrical machine (G), wherein A belt-shaped core sheet (10) made of a magnetic plate (100) is used as an iron core material, and the core sheet (10) is formed in an annular shape and laminated in the axial direction, thereby forming a cylindrical shape as a whole. The laminated core (1) is configured,
The core sheet (10) alternately has teeth (11) and slots (12) for winding the stator coil (C) on the inner peripheral side, and the teeth (11) on the outer peripheral side. In the stator core (D) of the rotating electrical machine (G) having a yoke portion (13) that connects the slot portions (12) at a predetermined pitch,
The core sheet (10) has a deep groove portion (17) at a boundary portion between the teeth portion (11) and the slot portion (12).
The deep groove portion (17) penetrates in the thickness direction of the core sheet (10), and is recessed in a tapered shape from the bottom surface (12a) of the slot portion (12) toward the outer diameter direction. It has a triangular shape that bites into (13), and
The deep groove portion (17) has a circumferential length (width W) of an opening portion (17a) opening toward the inner diameter direction on the bottom surface (12a) side of the strand of the stator coil (C). It is smaller than the thickness (C1),
The yoke portion (13) has a thick portion (14) whose inner peripheral side to the deepest portion of the deep groove portion (17) has the same plate thickness as that of the teeth portion (11). The stator core (D) of the rotating electrical machine (G) is characterized in that the outer peripheral side of the meat portion (14) forms a tapered thin-wall portion (15) whose plate thickness gradually decreases toward the outer diameter direction. ). In the stator core (D) of the rotating electrical machine (G) according to claim 1 ,
The deep groove portion (17) is attached to both sides in the circumferential direction of the bottom surface (12a) of the slot portion (12),
The maximum circumferential width from the opening edge of one of the deep groove portions (17) to the opening edge of the other deep groove portion (17) is the same as the circumferential width of the slot portion (12). a stator core of a rotating electrical machine (G), characterized in that there (D). In the stator core (D) of the rotating electrical machine (G) according to claim 2 ,
The yoke portion (13) has a thick portion (14) whose inner peripheral side to the deepest portion of the deep groove portion (17) has the same plate thickness as that of the teeth portion (11). The stator core (D) of the rotating electrical machine (G) is characterized in that the outer peripheral side of the meat portion (14) forms a tapered thin-wall portion (15) whose plate thickness gradually decreases toward the outer diameter direction. ). In the stator core (D) of the rotating electrical machine (G) according to claim 3 or claim 5 ,
The stator coil (C) is a stator core (D) of a rotating electrical machine (G), wherein a rectangular wire having a rectangular cross section is used as an element wire . In the stator core (D) of the rotating electrical machine (G) according to any one of claims 3, 5, or 6,
The yoke portion (13) has a fixing notch (16) recessed from the outer peripheral surface toward the inner diameter direction.
With
The bottom surface (16a) of the fixing notch (16) has the thick portion (14) and the thin portion (1).
5) A stator core (D) of a rotating electrical machine (G), which is located in the vicinity of a boundary line with 5) . In the stator core (D) of the rotating electrical machine (G) according to any one of claims 1 to 7,
The regions of the plastic deformation phenomenon that occur on the inner peripheral side and the outer peripheral side of the core sheet (10) when the core sheet (10) is formed into an annular shape are called a compression side deformation region and a tension side deformation region, respectively. When the region that borders the two regions and does not compress or expand is called a neutral line (10X),
A stator core (D) of a rotating electrical machine (G), wherein a deepest portion of the deep groove portion (17) is positioned on an inner diameter side including the neutral line (10X). A method for manufacturing a stator core (D) of a rotating electrical machine (G) according to any one of claims 1 to 8,
In the process of producing the belt-shaped core sheet (10) having the teeth (11), the slot (12) and the yoke (13) from the magnetic plate (100), the teeth (11) and As an intermediate shape of the deep groove portion (17), a triangular expansion groove portion (17X) in which the opening portion (17a) is greatly expanded is positioned at a boundary portion with the slot portion (12). A core sheet manufacturing process to be formed;
In the process of forming the core sheet (10) into an annular shape so that the yoke portion (13) is on the outer peripheral side, by narrowing the opening of the expansion groove (17X) from the circumferential direction, The circumferential length (width W) of the opening (17a) opening toward the inner diameter direction on the bottom surface (12a) side of the slot (12) is the thickness of the strand of the stator coil (C). (C1) The manufacturing method of the stator core (D) of a rotary electric machine (G) characterized by including the winding process which forms the said deep groove part (17) made smaller.

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