JP7046265B2 - How to make an armature core, how to make an electric machine, and an electric machine - Google Patents

Description

The present invention relates to a method for manufacturing an armature core formed by laminating a plurality of iron core pieces, a method for manufacturing an electric machine, and an electric machine.

Conventionally, the stator core of an electric motor is made by punching out a plurality of annular core pieces to which a part of the outer circumference is connected from a steel plate sheet, and alternately folding and stacking the core pieces in opposite directions at each connecting portion. It is formed (see, for example, Patent Document 1).

Jitsukaisho 62-145450

In the conventional stator core as described above, a plurality of annular core pieces are punched out from one steel plate sheet. Therefore, there is a problem that the material in the central portion of each iron core piece is discarded and there is a large amount of material loss.

The present invention has been made to solve the above-mentioned problems, and obtains an armature core manufacturing method, an electric machine manufacturing method, and an electric machine capable of reducing material loss of a steel plate sheet.

In the method for manufacturing an armature core according to the present invention, a plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and the plurality of iron core pieces are connected. A process of cutting out an iron core piece set in which a plurality of connecting portions are provided between the iron core pieces from a steel plate sheet, and bending the cut out iron core piece set at each connecting portion, laminating each iron core piece, and dividing and laminating the iron core. Each connecting portion in the iron core piece set is partially provided between the back yoke portions of two adjacent iron core pieces, and each back yoke portion in the iron core piece set is a connecting portion. Other than that, it is far from the adjacent back yoke part.
Further, in the method for manufacturing an armature core according to the present invention, a plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of iron core pieces are arranged. A process of cutting out an iron core piece set in which a plurality of connecting portions are provided between the iron core pieces from a steel plate sheet, and bending the cut out iron core piece set at each connecting portion to stack and divide each iron core piece. Each back yoke portion has a yoke end portion which is an end portion on the opposite side to the teeth portion, and each teeth portion has a yoke end portion on the opposite side to the back yoke portion. It has a tooth tip that is an end, and the plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips, and the plurality of connecting portions are arranged so as to alternately abut each other. It has a plurality of yoke connecting portions and a plurality of teeth connecting portions, and each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends, and each teeth connecting portion in the iron core piece set is provided. The portion is partially provided between the two adjacent tooth tips, and each tooth portion in the iron core piece set is separated from the adjacent teeth portion except for the teeth connecting portion.
Further, in the method for manufacturing an armature core according to the present invention, a plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of iron core pieces are arranged. A process of cutting out a series of iron core piece sets in which a plurality of iron core piece sets in which a plurality of connecting portions are provided between the iron core pieces are further connected from a steel plate sheet, and a plurality of cut out series of iron core piece sets. Among the connecting portions of the above, each of the connecting portions has a step of bending at a connecting portion provided between the core piece sets and laminating the core piece sets to form a linear laminated iron core. The connecting portion is partially provided between the back yoke portions of two adjacent iron core pieces, and each back yoke portion in each core piece set is separated from the adjacent back yoke portion in the portion other than the connecting portion. There is.
Further, the electric machine according to the present invention has an armature having an armature core and a field facing the armature through a gap and moving relative to the armature. The armature core has a plurality of divided laminated iron cores arranged along the moving direction of the field, and each divided laminated iron core is configured by laminating a plurality of iron core pieces, and each armature piece is It has a back yoke portion and a teeth portion protruding from the back yoke portion to the field side, and each divided laminated core has a plurality of bent core pieces connected to each other in the stacking direction. Bent portions are provided, and each bent portion is partially provided at the end of the back yoke portion in the direction of movement of the field magnet.
Further, the electric machine according to the present invention has an armature having an armature core and a field facing the armature through a gap and moving relative to the armature. The armature core has a plurality of divided laminated iron cores arranged along the moving direction of the field, and each divided laminated iron core is configured by laminating a plurality of iron core pieces, and each core piece is , A back yoke portion and a teeth portion protruding from the back yoke portion to the field side, and each back yoke portion has a yoke end portion which is an end portion on the opposite side to the teeth portion. Each tooth portion has a tooth tip portion which is an end portion opposite to the back yoke portion, and each divided laminated iron core is bent by connecting between adjacent iron core pieces in the stacking direction. A plurality of inter-yoke bending portions and a plurality of inter-teeth bending portions are provided, each yoke-interfolding portion is provided at the yoke end portion, and each tooth-to-teeth bending portion is partially provided at the tooth tip portion. Has been done.

According to the method for manufacturing an armature core, the method for manufacturing an electric machine, and the electric machine of the present invention, it is possible to reduce the material loss when manufacturing the armature core.

It is a top view which shows the stator core manufactured by the manufacturing method of the stator core in Embodiment 1 of this invention. It is a top view which shows the iron core piece set in which one divided laminated iron core which constitutes the stator core of FIG. 1 is formed. It is a perspective view which shows the process of forming the divided laminated iron core by the iron core piece set of FIG. FIG. 3 is a plan view showing a state in which three divided laminated iron cores formed in FIG. 3 are connected in the circumferential direction. It is a top view which shows the steel plate sheet in which two sets of iron core pieces of FIG. 2 are arranged. It is a top view which shows the steel plate sheet which arranged the iron core piece set in Embodiment 2 of this invention. It is a perspective view which shows the process of forming the divided laminated iron core by the iron core piece set of FIG. FIG. 3 is a plan view showing a state in which four iron core piece sets of FIG. 6 are arranged side by side in the circumferential direction and arranged on a steel plate sheet. FIG. 3 is a perspective view showing a state in which four iron core piece sets cut out from the steel plate sheet of FIG. 8 are bent. It is a figure which shows the relationship between the number of iron core piece sets arranged in a steel plate sheet, and the material yield of a steel plate sheet. It is a top view which shows the steel plate sheet which arranged two iron core piece sets in Embodiment 3 of this invention. It is a perspective view which shows the split laminated iron core formed by one iron core piece set cut out from the steel plate sheet of FIG. It is a top view which shows the state which connected two the divided laminated iron cores of FIG. It is a top view which shows the steel plate sheet which arranged two iron core piece sets in Embodiment 4 of this invention. It is a perspective view which shows the process of forming the divided laminated iron core by one iron core piece set cut out from the steel plate sheet of FIG. FIG. 15 is a plan view showing a state in which two divided laminated iron cores of FIG. 15 are connected. It is a top view which shows the steel plate sheet in which the iron core piece set in Embodiment 5 of this invention is arranged. It is a top view which shows the split laminated iron core formed by bending each connecting part of the iron core piece set of FIG. 17 alternately. FIG. 3 is a plan view showing a state in which the side end forming portion of each core piece constituting the divided laminated iron core of FIG. 18 is rotationally moved toward the back yoke portion. It is a top view which shows the split laminated iron core in Embodiment 5 of this invention. It is a top view which shows the modification of the iron core piece set in Embodiment 5 of this invention. It is a top view which shows the steel plate sheet which arranged two iron core pieces set of Embodiment 6 of this invention in the opposite direction, and staggered. It is a top view which shows the iron core piece set cut out from the steel plate sheet of FIG. It is a perspective view which shows the laminated iron core formed by the iron core piece set of FIG. 23. It is a top view which shows the process of forming an annular stator core using the laminated iron core of FIG. 24. It is a perspective view which shows the rotary electric machine according to Embodiment 7 of this invention. It is a top view which shows the rotary electric machine of FIG. It is a top view which shows the iron core piece set constituting the divided laminated iron core of FIG. 27. FIG. 8 is an enlarged plan view showing a main part of FIG. 28. It is a perspective view which shows the process of forming the divided laminated iron core by the iron core piece set of FIG. 28. It is a perspective view which shows the divided laminated iron core of FIG. 27. It is a flowchart which shows the process of forming the divided laminated iron core of Embodiment 7. It is a top view which shows the stator core by Embodiment 8 of this invention. FIG. 3 is an enlarged plan view showing a main part of FIG. 33. It is a top view which shows the iron core piece set by Embodiment 9 of this invention. It is a top view which shows the part A of FIG. 35 enlarged. It is a top view which shows the B part of FIG. 35 enlarged. It is a top view which shows the iron core piece set by Embodiment 10 of this invention. It is a top view which shows the C part of FIG. 38 enlarged. It is a top view which shows the D part of FIG. 38 enlarged. It is a perspective view which shows the process of forming the divided laminated iron core by the iron core piece set of FIG. 38. It is a top view which shows the stator core of Embodiment 10. FIG. FIG. 4 is an enlarged plan view showing a main part of FIG. 42. It is a top view which shows the modification of the stator core of Embodiment 10. FIG. It is a top view which shows the iron core piece of FIG. 44. It is a top view which shows the modification of the stator core of Embodiment 3. FIG. It is a top view which shows the iron core piece of FIG. 46. It is a top view which shows the two iron core pieces set by Embodiment 11 of this invention. It is a top view which shows the 1st modification of Embodiment 11. FIG. It is a top view which shows the 2nd modification of Embodiment 11. FIG. It is a top view which shows the 3rd modification of Embodiment 11. FIG. It is a top view which shows the 4th modification of Embodiment 11. FIG. It is a perspective view which shows an example of the linear motor to which this invention is applied.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

Embodiment 1.
FIG. 1 is a plan view showing a stator core 1 manufactured by the method for manufacturing a stator core according to the first embodiment of the present invention. The stator core 1 as an armature core 1 is formed in an annular shape by connecting a plurality of divided laminated cores 2 equally divided in the circumferential direction in the circumferential direction around the rotation axis of the stator core 1. .. In the following description, the direction along the rotation axis of the stator core 1 is referred to as "axial direction". The circumferential direction around the rotation axis of the stator core 1 is called the "circumferential direction". The radial direction around the rotation axis of the stator core 1 is called the "radial direction".

FIG. 2 is a plan view showing an iron core piece set 20 constituting the divided laminated iron core 2 of FIG. In this example, the iron core piece set 20 is composed of seven iron core pieces 21. Each iron core piece 21 has a back yoke portion 21B and a teeth portion 21T, respectively. Each tooth portion 21T protrudes from the back yoke portion 21B. A plurality of connecting portions 201 for connecting a plurality of iron core pieces 21 are provided between the iron core pieces 21 in the iron core piece set 20. That is, the seven iron core pieces 21 are connected to the adjacent iron core pieces 21 by the connecting portion 201, respectively. Each connecting portion 201 is provided between adjacent back yoke portions 21B at the circumferential end of each iron core piece 21. The iron core pieces 21 are arranged so that the back yoke portions 21B are directed in the same direction and the radially outer ends of the back yoke portions 21B are aligned in a straight line.

Each connecting portion 201 in the iron core piece set 20 is partially provided between the back yoke portions 21B of two adjacent iron core pieces 21. Each back yoke portion 21B in the iron core piece set 20 is separated from the adjacent back yoke portion 21B except for the connecting portion 201.

FIG. 3 is a perspective view showing a process of forming the split laminated iron core 2 from the iron core piece set 20 of FIG. Each iron core piece 21 constituting the iron core piece set 20 is bent in different directions at each connecting portion 201. At this time, the iron core piece set 20 is bent so that one surface of the iron core piece 21 faces each other. Each iron core piece 21 bent at each connecting portion 201 is laminated in the axial direction to form a divided laminated iron core 2. Here, forming the divided laminated iron core 2 by bending and laminating the iron core piece set 20 corresponds to the "step of laminating the iron core pieces to form the divided laminated iron core".

A bent portion 21a is formed in each of the bent connecting portions 201. In this example, the bent portions 21a are formed on the side surfaces 2C on both sides of the divided laminated iron core 2 in the circumferential direction. No connecting portion is provided on the radial end faces of the back yoke portion 21B and the teeth portion 21T of the divided laminated iron core 2. Therefore, no bent portion is formed in the back yoke portion 21B and the teeth portion 21T. Therefore, the divided laminated iron core 2 of the first embodiment can improve the flatness of the end faces of the back yoke portion 21B and the teeth portion 21T.

FIG. 4 is a plan view showing a state in which three divided laminated iron cores 2 of FIG. 3 are connected in the circumferential direction. As shown in FIG. 4, a plurality of divided laminated cores 2 are joined in the circumferential direction to form an annular stator core 1. Here, forming the annular stator core 1 by connecting a plurality of the divided laminated iron cores 2 in the circumferential direction corresponds to the "step of connecting a plurality of the divided laminated iron cores in an annular shape".

FIG. 5 is a plan view showing a steel plate sheet 200 in which two iron core piece sets 20 of FIG. 2 are arranged. In this example, the two iron core piece sets 20 are alternately arranged on the steel plate sheet 200 with the back yoke portions 21B facing outward. At both ends of the steel plate sheet 200 along the longitudinal direction, the radial outer ends of the back yoke portion 21B of each iron core piece 21 constituting each iron core piece set 20 are linearly arranged. Therefore, unnecessary portions 8 are not generated at both ends of the steel sheet sheet 200 along the longitudinal direction.

In the two core piece sets 20, each tooth portion 21T is inserted and arranged in the space between two adjacent tooth portions 21T of the other iron core piece set 20. Therefore, the width in the direction perpendicular to the longitudinal direction of the steel plate sheet 200 is smaller than the sum of the radial lengths of the two iron core piece sets 20.

The two iron core piece sets 20 are punched out from the steel plate sheet 200 by a pressing device or the like. Here, punching out the two iron core piece sets 20 from the steel plate sheet 200 corresponds to the "process of cutting out the iron core piece set from the steel plate sheet". The steel plate sheet 200 is divided into a portion where the iron core piece set 20 is punched out and an unnecessary portion 8 other than that. The unnecessary portion 8 is a portion that is discarded after the iron core piece set 20 is punched out, and is a portion that causes material loss. In this example, the unnecessary portion 8 is between the adjacent teeth portions 21T of each iron core piece set 20.

In the following description, the minute unnecessary part generated at the connecting portion of each iron core piece and the minute unnecessary part generated by the uneven shape formed on the radial outer side of the back yoke portion 21B of each iron core piece will be described. , The description as an unnecessary part is omitted.

As described above, the method for manufacturing the stator core in the first embodiment includes a step of forming the split laminated core 2 from the core piece set 20 and a step of connecting a plurality of the split laminated cores 2 in an annular shape. The stator core 1 is composed of a plurality of divided laminated cores 2. The divided laminated iron core 2 is composed of an iron core piece set 20 in which a plurality of iron core pieces 21 are arranged in a straight line. On the steel sheet sheet 200, two iron core piece sets 20 are arranged in opposite directions and alternately. Therefore, the unnecessary portion 8 of the steel plate sheet 200 is formed only in the region between the teeth portions 21T of the two iron core piece sets 20. Therefore, the material loss can be reduced as compared with the case of punching the annular iron core piece from the steel plate sheet.

In the method for manufacturing the stator core of the first embodiment, each core piece set 20 is cut out from the steel plate sheet 200 by punching. However, the method of cutting out each iron core piece set 20 from the steel plate sheet 200 is not limited to the punching process. For example, each iron core piece set 20 may be cut out from the steel plate sheet 200 by laser processing.

Further, in the first embodiment, the iron core piece set 20 is composed of seven iron core pieces 21. However, the number of iron core pieces 21 constituting the iron core piece set 20 may be 6 or less, or may be 8 or more.

Embodiment 2.
Next, a method for manufacturing the stator core according to the second embodiment will be described.

In the second embodiment, the position where the connecting portion for connecting the plurality of iron core pieces 21 constituting the iron core piece set 20 is provided is different from the method for manufacturing the stator core of the first embodiment. Other configurations are the same as those in the first embodiment.

FIG. 6 is a plan view showing a steel plate sheet 200 in which the iron core piece set 20 of the second embodiment is arranged. In this example, the iron core piece set 20 in which 16 iron core pieces 21 are linearly connected in the radial direction is arranged on the steel plate sheet 200. The number of iron core pieces 21 constituting the iron core piece set 20 is not limited to 16. That is, the number of iron core pieces 21 may be 15 or less or 17 or more. The iron core pieces 21 constituting the iron core piece set 20 are arranged alternately with the back yoke portions 21B and the teeth portions 21T abutting each other.

In this example, each iron core piece 21 other than the iron core pieces 21 at both ends in the longitudinal direction of the steel plate sheet 200 is supported by the connecting portion 202 provided in the back yoke portion 21B and the connecting portion 203 provided in the teeth portion 21T. It is connected to the iron core piece 21 of. The iron core pieces 21 at both ends of the steel plate sheet 200 in the longitudinal direction are connected to the other iron core pieces 21 by the connecting portion 203 provided on the teeth portion 21T. In this example, unnecessary portions 8 are formed on both sides of the tooth portion 21T in the circumferential direction.

FIG. 7 is a perspective view showing a process of forming a split laminated iron core 2 from the iron core piece set 20 after cutting out the iron core piece set 20 from the steel plate sheet 200 of FIG. Each iron core piece 21 constituting the iron core piece set 20 is bent in different directions at the connecting portions 202 and 203. At this time, the iron core piece set 20 is bent so that one surface of the iron core piece 21 faces each other. The divided laminated iron core 2 is formed by laminating the iron core pieces 21 bent at the connecting portions 202 and 203.

A bent portion 21a is formed in each of the bent connecting portions 202 and 203. In this example, the bent portion 21a is formed on the radial end faces of the back yoke portion 21B and the teeth portion 21T of the divided laminated iron core 2.

FIG. 8 is a plan view showing a state in which four iron core piece sets 20 of FIG. 6 are arranged in a direction perpendicular to the longitudinal direction and arranged on a steel plate sheet 200. FIG. 9 is a perspective view showing a state in which the four iron core piece sets 20 cut out from the steel plate sheet 200 of FIG. 8 are bent without being separated.

As described above, according to the method for manufacturing the stator core in the second embodiment, the core pieces 21 of the iron core piece set 20 arranged on the steel plate sheet 200 have the back yoke portions 21B and the teeth portions 21T butted against each other. , Are arranged in a straight line and staggered. Therefore, the unnecessary portion 8 of the steel plate sheet 200 is formed only at the end portion in the direction perpendicular to the longitudinal direction of the steel plate sheet 200. Therefore, the amount of material loss generated when the iron core piece set 20 is cut out from the steel plate sheet 200 can be further reduced.

Further, no connecting portion is provided on the side surfaces 2C on both sides of the divided laminated iron core 2 in the circumferential direction. Therefore, no bent portion is formed on the side surfaces 2C on both sides in the circumferential direction. Therefore, the divided laminated iron core 2 can improve the dimensional accuracy of the side surfaces 2C on both sides in the circumferential direction. Therefore, when the plurality of divided laminated iron cores 2 are connected to each other by the side surface 2C in the circumferential direction to form the annular stator core 1, the plurality of divided laminated iron cores 2 can be connected with high accuracy.

The number of iron core piece sets 20 arranged on the steel plate sheet 200 is not limited to four. For example, the iron core piece set 20 arranged on the steel plate sheet 200 may be two, three, or five or more.

FIG. 10 is a diagram showing the relationship between the number of iron core piece sets 20 arranged on the steel plate sheet 200 and the material yield of the steel plate sheet 200. The horizontal axis of FIG. 10 shows the number of iron core piece sets 20 arranged on the steel plate sheet 200. The vertical axis of FIG. 10 shows the material yield of the steel sheet sheet 200. As shown in FIG. 10, the larger the number of the iron core piece sets 20 arranged on the steel plate sheet 200, the higher the material yield. That is, the larger the number of the iron core piece sets 20 arranged on the steel plate sheet 200, the smaller the material loss.

Embodiment 3.
Next, a method for manufacturing the stator core according to the third embodiment will be described.

In the third embodiment, the shape of the iron core piece 21 is different from that of the first and second embodiments. Other configurations are the same as those in the first embodiment.

FIG. 11 is a plan view showing a steel plate sheet 200 in which two iron core piece sets 20 according to the third embodiment of the present invention are arranged. The two iron core piece sets 20 are alternately arranged on the steel plate sheet 200 with the back yoke portions 21B facing outward. At both ends of the steel sheet sheet 200 along the longitudinal direction, the radial outer ends of the back yoke portions 21B are linearly arranged.

In the two core piece sets 20, each tooth portion 21T is inserted and arranged in the space between two adjacent tooth portions 21T of the other iron core piece set 20. Therefore, the width in the direction perpendicular to the longitudinal direction of the steel plate sheet 200 is smaller than the sum of the radial lengths of the two iron core piece sets 20.

In this example, similarly to the steel plate sheet 200 of the first embodiment, the unnecessary portion 8 is formed between the adjacent teeth portions 21T of each iron core piece set 20.

A semicircular convex portion 25 is formed at one end in the circumferential direction of the back yoke portion 21B of each iron core piece 21 constituting the iron core piece set 20. Further, a semicircular fitting recess 26 is formed at the other end of the back yoke portion 21B of each iron core piece 21 in the circumferential direction. The convex portion 25 and the fitting concave portion 26 of each iron core piece 21 are formed in a shape that allows them to be fitted to each other.

Each iron core piece 21 is connected to each other by a connecting portion 205 provided in the convex portion 25 and a connecting portion 206 provided in the fitting recess 26. The connecting portion 205 on one side and the connecting portion 206 on the other side in the width direction of each back yoke portion 21B are provided at different positions in the protruding direction of the teeth portion 21T from the back yoke portion 21B.

FIG. 12 is a perspective view showing a split laminated iron core 2 formed by one iron core piece set 20 cut out from the steel plate sheet 200 of FIG.

Each of the iron core pieces 21 constituting the iron core piece set 20 is bent in different directions at the connecting portions 205 and 206. The iron core pieces 21 bent at the connecting portions 205 and 206 are laminated to form the divided laminated iron core 2.

FIG. 13 is a plan view showing a state in which two divided laminated iron cores 2 of FIG. 12 are connected in the circumferential direction. The divided laminated iron cores 2 are positioned with each other by fitting the convex portion 25 into the fitting recess 26 of the other divided laminated iron core 2. Therefore, in the work of connecting the plurality of divided laminated iron cores 2 in the circumferential direction, the radial positioning of each divided laminated iron core 2 becomes easy.

As described above, according to the method for manufacturing the stator core in the third embodiment, the divided laminated iron core 2 is composed of the iron core piece set 20 in which a plurality of iron core pieces 21 are linearly arranged. On the steel sheet sheet 200, two iron core piece sets 20 are arranged in opposite directions and alternately. Therefore, the unnecessary portion 8 of the steel plate sheet 200 is formed only in the region between the teeth portions 21T of the two iron core piece sets 20. Therefore, the material loss can be reduced as compared with the case of punching the annular iron core piece from the steel plate sheet.

Further, a convex portion 25 is formed at one end of the back yoke portion 21B of each iron core piece 21 in the circumferential direction, and a fitting recess 26 is formed at the other end. Then, when the iron core pieces 21 are arranged in the circumferential direction, the convex portion 25 and the fitting concave portion 26 are fitted to each other so that the core pieces 21 are positioned in the radial direction. Therefore, the iron core pieces 21 can be easily arranged in the circumferential direction.

In the third embodiment, the shape of the convex portion 25 and the fitting concave portion 26 of each iron core piece 21 is semicircular. However, the shapes of the convex portion 25 and the fitting concave portion 26 are not limited to this. For example, the shape of the convex portion 25 and the fitting concave portion 26 may be trapezoidal. By making the top of the convex portion 25 linear, the length of the connecting portion 205 can be increased. As a result, the rigidity of the connecting portion 205 can be increased.

Further, the sizes of the convex portion 25 and the fitting concave portion 26 formed in each iron core piece 21 can be appropriately changed. For example, in the case of the stator core 1 in which the distance between the iron core pieces 21 is large, the sizes of the convex portion 25 and the fitting concave portion 26 may be increased. This makes it possible to further facilitate the radial positioning of each iron core piece 21.

The convex portion 25 and the fitting recess 26 in the iron core piece 21 of the third embodiment can also be applied to the iron core piece 21 of the first embodiment.

Embodiment 4.
Next, a method for manufacturing the stator core according to the fourth embodiment will be described.

The fourth embodiment is different from the first to third embodiments in that the iron core piece is further divided. Other configurations are the same as those in the second embodiment.

FIG. 14 is a plan view showing a steel plate sheet 300 in which two split iron core piece sets 30 are arranged according to the fourth embodiment of the present invention. The split core piece set 30 has a shape obtained by bisecting the iron core piece set 20 of the second embodiment by a straight line extending in the radial direction about the rotation axis of the stator core 1. That is, the divided iron core piece set 30 of the fourth embodiment is composed of the two divided iron core pieces 31 obtained by dividing the iron core piece 21 of the second embodiment into two along the radial direction.

The split core piece set 30 is configured by connecting five split core pieces 31 in a linear shape in the radial direction. The two-divided iron core pieces 31 are arranged alternately so that the back yoke portions 31B and the teeth portions 31T are butted against each other. The number of the two-divided core pieces 31 constituting the divided core piece set 30 is not limited to five.

On the steel sheet sheet 300, a pair of divided iron core piece sets 30 are arranged in a state of being meshed with each other with the divided linear end portions 30a of each of the two divided iron core pieces 31 facing outward.

In this example, each of the two-divided iron core pieces 31 other than the two-divided iron core pieces 31 at both ends of the steel plate sheet 300 in the longitudinal direction is connected to the connecting portion 301 provided in the back yoke portion 31B and the teeth portion 31T. It is connected to the other two-divided steel core piece 31 by the portion 302. The two-divided core pieces 31 at both ends of the steel plate sheet 300 in the longitudinal direction are connected to the other two-divided core pieces 31 by the connecting portion 301 provided in the back yoke portion 31B or the connecting portion 302 provided in the teeth portion 31T. Has been done.

Each of the two split core pieces 31 constituting the split core piece set 30 is bent in different directions at the connecting portions 301 and 302, respectively. By stacking the two-divided core pieces 31 bent at the connecting portions 301 and 302, the two-divided laminated core 3A as shown in FIG. 15 is formed. The two-divided laminated core 3A has a side surface 3C composed of each divided end portion 30a of each of the two-divided core pieces 31 laminated.

A pair of two-divided laminated iron cores 3A are formed from one steel plate sheet 300. The divided iron core piece set 30 arranged on the steel plate sheet 300 is not limited to a pair. For example, a plurality of a pair of divided iron core piece sets 30 shown in FIG. 14 may be arranged side by side in a direction perpendicular to the longitudinal direction of the divided iron core piece set 30 and arranged on the steel plate sheet 300.

As shown in FIG. 16, one divided laminated iron core 3 is formed by abutting and joining the side surfaces 3C of the pair of two divided laminated iron cores 3A. The stator core 1 is formed by connecting a plurality of the divided laminated cores 3 in the circumferential direction in an annular shape.

Here, it is possible to form one divided laminated core 3 by bending the two-divided core piece 31 to form the two-divided laminated core 3A and abutting and joining the side surfaces 3C of the pair of two-divided laminated cores 3A. , "A step of laminating each of the two-divided core pieces to form a pair of two-divided laminated cores and joining each side surface of the pair of two-divided laminated cores to form the divided laminated cores".

A bent portion 31a is formed at each of the connecting portions 301 and 302 of each of the two-divided laminated cores 3A constituting the divided laminated core 3. In this example, the bent portion 31a is formed in the back yoke portion 31B and the teeth portion 31T of each of the two-divided laminated iron cores 3A. Bent portions are not provided on the side surfaces of each of the two-divided laminated iron cores 3A in the circumferential direction. Therefore, the dimensional accuracy can be improved on the side surfaces of each of the two-divided laminated iron cores 3A on both sides in the circumferential direction. Therefore, when the side surfaces 3C of the pair of two-divided laminated iron cores 3A are butted against each other and bonded, the bonding can be performed with high accuracy.

As described above, according to the method for manufacturing the stator core in the fourth embodiment, the split core piece set 30 divides the iron core piece 21 of the second embodiment into two in the radial direction. It is composed of pieces 31. The two divided iron core pieces 31 constituting the divided iron core piece set 30 are connected to each other by abutting the back yoke portions 31B and the teeth portions 31T and alternately.

On the steel sheet sheet 300, a pair of divided iron core piece sets 30 are arranged in a state of being meshed with each other with the divided linear end portions 30a of each of the two divided iron core pieces 31 facing outward. Therefore, both ends of the steel sheet sheet 300 in the direction perpendicular to the longitudinal direction are linear.

Further, no gap is formed between the pair of divided iron core piece sets 30 arranged on the steel plate sheet 300. Therefore, the unnecessary portion 8 is not formed on the steel sheet sheet 300. As a result, the material loss generated when the divided iron core piece set 30 is cut out from the steel plate sheet 300 can be significantly reduced. In FIG. 14, two divided iron core piece sets 30 are arranged, but two or more may be used.

Embodiment 5.
Next, a method for manufacturing the stator core according to the fifth embodiment will be described.

In the fifth embodiment, the shape of each iron core piece 41 is different from that of the first to fourth embodiments. Other configurations are the same as those in the second embodiment.

FIG. 17 is a plan view showing a steel plate sheet 400 in which the iron core piece set 40 according to the fifth embodiment of the present invention is arranged.

In this example, one iron core piece set 40 in which eight iron core pieces 41 are linearly connected in the radial direction is arranged on the steel plate sheet 400. The iron core pieces 41 are arranged alternately so that the back yoke portions 41B and the teeth portions 41T are butted against each other.

Each iron core piece 41 arranged other than both ends in the longitudinal direction of the iron core piece set 40 has another iron core piece 41 by the connecting portion 401 provided in the back yoke portion 41B and the connecting portion 402 provided in the teeth portion 41T. Is linked with. The iron core pieces 41 arranged at both ends in the longitudinal direction of the iron core piece set 40 are connected to the other iron core pieces 41 by the connecting portion 401 provided in the back yoke portion 41B.

As shown in FIG. 17, the outer shape of each iron core piece 41 constituting the iron core piece set 40 is rectangular. Each iron core piece 41 is linearly connected along the radial direction. Therefore, the outer shape of the iron core piece set 40 is rectangular.

The width of the iron core piece set 40 in the direction perpendicular to the longitudinal direction is equivalent to the width of the steel plate sheet 400. The length in the longitudinal direction of the iron core piece set 40 is equivalent to the length in the longitudinal direction of the steel plate sheet 400. Therefore, the iron core piece set 40 substantially overlaps with the steel plate sheet 400.

FIG. 18 is a plan view showing a split laminated iron core 4 formed by alternately bending the connecting portions 401 and 402 of the iron core piece set 40 of FIG. 17 and laminating the iron core pieces 41.

Side end forming portions 42, 43 constituting the side end portions of the back yoke portion 41B are provided on both side portions in the circumferential direction of the tooth portions 41T of each iron core piece 41 constituting the divided laminated iron core 4. One end side of the side end forming portions 42 and 43 is connected to the iron core piece 41 by connecting portions 42a and 43a formed near the root of the tooth portion 41T of the iron core piece 41. The other ends of the side end forming portions 42 and 43 are free ends, respectively.

The side end forming portions 42 and 43 are moved after the connecting portions 401 and 402 of the iron core piece set 40 are alternately bent and laminated.

FIG. 19 is a plan view showing a state in which the side end forming portions 42 and 43 of each iron core piece 41 constituting the divided laminated iron core 4 of FIG. 18 are rotationally moved to the back yoke portion 41B side.

The other ends of the side end forming portions 42 and 43 are rotationally moved by 180 ° or substantially 180 ° from the teeth portion 41T side to the back yoke portion 41B side around the connecting portions 42a and 43a. Then, the side end forming portions 42 and 43 are moved to both sides in the circumferential direction on the back yoke portion 41B side. As a result, as shown in FIG. 20, the shape of the divided laminated iron core 4 becomes the same as the shape of the divided laminated iron core 2 formed in the first embodiment.

Here, after each iron core piece 41 is laminated to form the divided laminated iron core 4, the other end side of each of the side end forming portions 42 and 43 is rotationally moved to the back yoke portion 41B side around the connecting portions 42a and 43a. To move the side end forming portions 42 and 43 to both sides in the circumferential direction on the back yoke portion 41B side, "after laminating the iron core pieces, the other end side of each side end forming portion is connected to the connecting portion. It corresponds to the process of rotating the back yoke portion toward the back yoke portion as a center and moving the back yoke portion to both sides in the circumferential direction.

As described above, according to the method for manufacturing the stator core according to the fifth embodiment, each of the core pieces 41 has side ends constituting the side ends of the back yoke portion 41B on both side portions in the circumferential direction of the teeth portion 41T. Forming portions 42 and 43 are provided to form a rectangular shape. The iron core piece set 40 is formed by connecting each iron core piece 41 in a straight line along the longitudinal direction and forming a rectangular shape. The outer diameter of the iron core piece set 40 substantially overlaps with the outer diameter of the steel plate sheet 400.

Therefore, the unnecessary portion 8 is not formed on the steel plate sheet 400 in which the iron core piece set 40 is arranged. Therefore, the material loss generated when the iron core piece set 40 is cut out from the steel plate sheet 400 can be significantly reduced.

In the fifth embodiment, the iron core piece set 40 connects each iron core piece 41 linearly along the radial direction. However, the arrangement of each iron core piece 41 constituting the iron core piece set 40 is not limited to this. For example, each iron core piece 41 constituting the iron core piece set 40 may be arranged linearly along the circumferential direction as in the modified example shown in FIG.

Each iron core piece 41 is connected by a connecting portion 403 provided on the side portion in the circumferential direction of the adjacent iron core piece 41. Also in the case of this modification, the iron core piece set 40 is formed in a rectangular shape. Further, the outer shape of the iron core piece set 40 substantially overlaps with the outer shape of the steel plate sheet 400. Therefore, the unnecessary portion 8 is not formed on the steel plate sheet 400 in which the iron core piece set 40 is arranged. Therefore, the same effect as that of the iron core piece set 40 of the fifth embodiment can be obtained.

In the case of this modification, the iron core piece set 40 is cut out from the steel plate sheet 400 and bent alternately at the connecting portion 403 to form the divided laminated iron core 4. After that, the side end forming portions 42 and 43 of each iron core piece 41 are moved to both sides in the circumferential direction on the back yoke portion 41B side. As a result, the divided laminated iron core 4 of the modified example has the same shape as the shape of the divided laminated iron core 2 formed in the first embodiment.

Embodiment 6.
Next, the method for manufacturing the stator core according to the sixth embodiment will be described.

The sixth embodiment is different from the first to fifth embodiments in that a plurality of iron core piece sets 50a are connected to form a series of iron core pieces 50.

FIG. 22 is a plan view showing a steel plate sheet 500 in which two series of iron core pieces 50 according to the sixth embodiment are arranged. In this example, the two series of iron core pieces 50 are alternately arranged on the steel plate sheet 500 with the back yoke portion 51B facing outward. At both ends of the steel sheet sheet 500 along the longitudinal direction, radial outer ends of each back yoke portion 51B constituting a series of iron core pieces 50 are lined up. Therefore, it is possible to reduce the unnecessary portions 8a generated on both ends along the longitudinal direction of the steel sheet sheet 200.

In the two series of iron core pieces 50, each tooth portion 51T is inserted and arranged in the space between two adjacent tooth portions 51T of the other series of iron core pieces 50. Therefore, the width in the direction perpendicular to the longitudinal direction of the steel plate sheet 500 can be made smaller than the sum of the radial lengths of the two iron core pieces 51.

FIG. 23 is a plan view showing a series of iron core pieces 50 cut out from the steel plate sheet 500 of FIG. 22. The series of iron core pieces 50 is composed of a plurality of iron core piece sets 50a in which nine iron core pieces 51 are set as a set. Each iron core piece set 50a is connected by a connecting portion 501 provided for each of the nine iron core pieces 51. Each iron core piece 51 constituting a series of iron core pieces 50 is linearly connected in the circumferential direction. An iron core piece notch 502 is formed between the iron core pieces 51.

FIG. 24 is a perspective view showing a linear laminated iron core 5 formed by using the series of iron core pieces 50 of FIG. 23. A series of iron core pieces 50 cut out from the steel plate sheet 500 are alternately bent and laminated at each connecting portion 501. As a result, the linear laminated iron core 5 is formed.

FIG. 25 is a plan view showing a process of forming an annular stator core from the linear laminated core 5 of FIG. 24. The linear laminated iron core 5 is formed into an annular shape by bending each core piece notch 502 inward in the radial direction. As a result, an annular stator core is formed.

As described above, according to the method for manufacturing a stator core according to the sixth embodiment, a series of iron core pieces 50 in which a plurality of core pieces 51 are linearly connected in the circumferential direction are arranged on the steel plate sheet 500. A series of iron core pieces 50 cut out from the steel plate sheet 500 are alternately bent and laminated at each connecting portion 501 to form a linear laminated iron core 5. Then, the linear laminated core 5 is formed into an annular shape to form a stator core. Therefore, the material loss can be significantly reduced as compared with the case where the annular core piece is punched from the steel plate sheet as in the case of the conventional stator core.

Further, an iron core piece notch 502 is formed between each iron core piece 51 constituting a series of iron core pieces 50. Therefore, it is possible to easily form the linear laminated iron core 5 into an annular shape.

In the sixth embodiment, a series of iron core pieces 50 are alternately bent and laminated at each connecting portion 501 to form a linear laminated iron core 5. However, the method for forming the linear laminated iron core 5 is not limited to this. For example, the linear laminated iron core 5 may be formed by cutting a series of iron core pieces 50 at each connecting portion 501 and laminating each cut iron core piece set. Further, the linear laminated iron core 5 may be formed by individually cutting out each set of iron core pieces from the steel plate sheet 500 and laminating them.

Embodiment 7.
Next, FIG. 26 is a perspective view showing a rotary electric machine according to the seventh embodiment of the present invention. 27 is a plan view showing the rotary electric machine of FIG. 26. 26 and 27 show a permanent magnet type rotary electric machine with 8 poles and 48 slots. However, the number of poles and the number of slots can be increased or decreased as appropriate.

The rotary electric machine as an electric machine has a cylindrical stator 101 as an armature, a cylindrical rotor 102 as a field magnet, and a shaft 103.

The stator 101 has a cylindrical stator core 1 and an armature winding 11. The stator 101 is composed of a plurality of divided laminated iron cores 2 as in the first to fifth embodiments. The winding method of the armature winding 11 may be either a distributed winding method or a centralized winding method. Further, the stator core 1 can be configured in the same manner as in the sixth embodiment.

The rotor 102 is arranged inside the stator 101. An annular gap 104 is interposed between the stator 101 and the rotor 102. The rotor 102 faces the stator 101 via the gap 104.

Further, the rotor 102 has a cylindrical rotor core 12 and a plurality of permanent magnets 13. The shaft 103 is inserted into the axial center of the rotor core 12. The rotor 102 moves relative to the stator 101. In this example, the rotor 102 rotates about the axis of the shaft 103 with respect to the stator 101 together with the shaft 103.

The shaft 103 is fixed to the rotor core 12 by a method such as adhesion, shrink fitting, or press fitting.

The rotor 102 of the present embodiment is an Interior Permanent Magnet type rotor. In the Interior Permanent Magnet type rotor, each permanent magnet 13 is embedded in the rotor core 12. However, it may be a Surface Permanent Magnet type rotor. In the Surface Permanent Magnet type rotor, each permanent magnet 13 is fixed to the outer periphery of the rotor core 12.

FIG. 28 is a plan view showing an iron core piece set 20 constituting the divided laminated iron core 2 of FIG. 27. In each iron core piece 21, the back yoke portion 21B has a yoke end portion 21Ba. The yoke end portion 21Ba is an end portion of the back yoke portion 21B and is an end portion on the opposite side of the teeth portion 21T.

In each iron core piece 21, the teeth portion 21T has a teeth tip portion 21Ta. The tooth tip portion 21Ta is an end portion of the tooth portion 21T and is an end portion on the opposite side of the back yoke portion 21B.

The plurality of iron core pieces 21 in the iron core piece set 20 are arranged so as to alternately abut the yoke end portions 21Ba and the tooth tip portions 21Ta. As a result, in the iron core piece set 20, the plurality of iron core pieces 21 are arranged along the direction parallel to the X axis of FIG. 28.

Further, the adjacent iron core pieces 21 in the iron core piece set 20 are connected at the yoke end portion 21Ba or the tooth tip portion 21Ta.

FIG. 29 is an enlarged plan view showing a main part of FIG. 28. A plurality of connecting portions are provided between the iron core pieces 21 in the iron core piece set 20. Each connecting portion connects two adjacent iron core pieces 21. Further, the plurality of connecting portions have a plurality of yoke connecting portions 207 and a plurality of teeth connecting portions 208.

Each yoke connecting portion 207 in the iron core piece set 20 is partially provided between two adjacent yoke end portions 21Ba. Each tooth connecting portion 208 in the iron core piece set 20 is partially provided between two adjacent tooth tip portions 21Ta.

An inter-yoke slit 20a and two yoke connecting portions 207 are provided between each yoke end portion 21Ba and the adjacent yoke end portion 21Ba in the iron core piece set 20. Each yoke slit 20a is provided between the two corresponding yoke connecting portions 207.

In this example, the inter-yoke slit 20a is arranged at the center of the back yoke portion 21B in the width direction. Further, the inter-yoke slit 20a is formed in a linear shape parallel to the width direction of the back yoke portion 21B.

The width direction of the back yoke portion 21B is a direction perpendicular to the protruding direction of the teeth portion 21T from the back yoke portion 21B, and is a direction parallel to the Y axis in FIG. 29. Further, the width direction of the back yoke portion 21B is a direction perpendicular to the connecting direction of the iron core pieces 21. The connecting direction of the iron core pieces 21 is the direction in which a plurality of iron core pieces 21 are lined up in the iron core piece set 20.

Further, the two yoke connecting portions 207 are arranged at both ends of the back yoke portion 21B in the width direction. Since the inter-yoke slit 20a is provided, each back yoke portion 21B in the iron core piece set 20 is separated from the adjacent back yoke portion 21B at a portion other than the yoke connecting portion 207.

An inter-teeth slit 20b and two teeth connecting portions 208 are provided between each tooth tip portion 21Ta and the adjacent tooth tip portion 21Ta in the iron core piece set 20. Each tooth-to-teeth slit 20b is provided between the two corresponding tooth-connecting portions 208.

In this example, the inter-teeth slit 20b is arranged at the center of the teeth portion 21T in the width direction. Further, the inter-teeth slit 20b is formed in a linear shape parallel to the width direction of the tooth portion 21T. The width direction of the teeth portion 21T is a direction parallel to the width direction of the back yoke portion 21B, that is, a direction parallel to the Y axis in FIG. 29.

Further, the two teeth connecting portions 208 are arranged at both ends of the teeth portion 21T in the width direction. By providing the inter-teeth slit 20b, each tooth portion 21T in the iron core piece set 20 is separated from the adjacent teeth portion 21T except for the teeth connecting portion 208.

Next, a method for manufacturing the divided laminated iron core 2 according to the seventh embodiment will be described. FIG. 30 is a perspective view showing a process of forming the divided laminated iron core 2 by the iron core piece set 20 of FIG. 28. Further, FIG. 31 is a perspective view showing the divided laminated iron core 2 of FIG. 27.

In the step of forming the divided laminated iron core 2, the plurality of teeth connecting portions 208 are bent so that the plurality of inter-teeth bent portions 22 are arranged in two rows along the laminating direction of the iron core pieces 21. Then, a tooth recess 2a is formed between the two rows of the plurality of inter-teeth bending portions 22, that is, in a portion corresponding to the plurality of inter-teeth slits 20b.

Further, in the step of forming the divided laminated iron core 2, the plurality of yoke connecting portions 207 are bent to form the plurality of bent portions 23 between the yokes in a state of being aligned in two rows along the laminating direction of the iron core pieces 21. To. Then, a yoke recess 2b is formed between the two rows of the plurality of inter-yoke bending portions 23, that is, in a portion corresponding to the plurality of inter-yoke slits 20a.

FIG. 32 is a flowchart showing a step of forming the divided laminated iron core 2 of the seventh embodiment. In the step of forming the divided laminated iron core 2, the steps S1 to S4 are repeatedly carried out.

In the iron core piece set 20, one of the two adjacent iron core pieces 21 is the first iron core piece, and the other is the second iron core piece. Step S101 is a step of fixing and positioning the first iron core piece. At this time, the first iron core piece is fixed by a fixing jig or a fixing device.

Step S102 is a step in which the connecting portion between the first iron core piece and the second iron core piece, that is, the yoke connecting portion 207 or the teeth connecting portion 208 is used as a reference for bending.

Step S103 is a step of bending the connecting portion between the first iron core piece and the second iron core piece and superimposing the second iron core piece on the first iron core piece. At this time, the connecting portion is bent by a bending jig or a bending device.

Step S104 is a step of releasing the first iron core piece and pressing the second iron core piece against the first iron core piece again in a state where the second iron core piece is overlapped with the first iron core piece. At this time, the second iron core piece is pressurized until the bent portion, that is, the bent portion between the yokes 23 or the bent portion 22 between the teeth is in a bent state without expanding.

Other configurations and manufacturing methods are the same as those in the second embodiment. Such a method for manufacturing the divided laminated iron core 2 is referred to as a vertical folding method.

Next, a method of assembling the rotary electric machine, that is, a manufacturing method will be described. First, the rotor core 12 is fixed to the shaft 103 by a method such as adhesion, shrink fitting, or press fitting. Subsequently, a plurality of permanent magnets 13 are fixed to the rotor core 12 by methods such as adhesion, gap fitting, and press fitting.

Further, a plurality of insulators (not shown) are fitted into the stator core 1 by a method such as adhesion or gap fitting. After that, the armature winding 11 is wound around the stator core 1. Finally, by inserting the rotor 102 into the stator 101, the rotary electric machine is assembled.

In such a configuration and manufacturing method of the seventh embodiment, each tooth connecting portion 208 in the iron core piece set 20 is partially provided between two adjacent tooth tip portions 21Ta. Therefore, the bent portion 22 between the teeth can be made smaller.

Further, the divided laminated iron core 2 is formed with a tooth recess 2a adjacent to a plurality of bent portions 22 between the teeth. As a result, a part of the member located inside the stator core 1 in the radial direction can be released to the tooth recess 2a.

In this example, it is possible to suppress the interference between the end portion of the split laminated iron core 2 on the radial inner side of the stator core 1 and the outer peripheral surface of the rotor 102. As a result, the size of the gap 104 can be made smaller.

Further, each yoke connecting portion 207 in the iron core piece set 20 is partially provided between two adjacent yoke end portions 21Ba. Therefore, the bent portion 23 between the yokes can be made smaller.

Further, the divided laminated iron core 2 is formed with yoke recesses 2b adjacent to the plurality of bent portions 23 between the yokes. As a result, a part of the member located on the radial outer side of the stator core 1 can be released to the yoke recess 2b.

Moreover, the same effect as that of the second embodiment can be obtained.

Further, the step of forming the divided laminated iron core 2 includes the steps of steps S101 to S104 described above. Therefore, it is possible to suppress the gap between the iron core pieces 21 and stabilize the shape of the divided laminated iron core 2.

Although omitted in the description of the second embodiment, also in the divided laminated iron core 2 of FIG. 7, a plurality of bent portions 21a are formed in a state of being arranged in two rows along the laminating direction of the iron core pieces 21. There is. Further, the plurality of bent portions 21a are provided at both ends in the width direction of the tip portions of the teeth. A tooth recess is formed between the two rows of the plurality of bent portions 21a.

Embodiment 8.
Next, FIG. 33 is a plan view showing the stator core 1 according to the eighth embodiment of the present invention. Further, FIG. 34 is an enlarged plan view showing a main part of FIG. 33. An annular frame 105 is fixed to the outer periphery of the stator core 1 of the eighth embodiment. The yoke end portion 21Ba of each iron core piece 21 is in contact with the inner peripheral surface of the frame 105. The frame 105 is fixed to the stator core 1 by, for example, shrink fitting.

A plurality of frame grooves 105a are provided on the inner peripheral surface of the frame 105. The frame grooves 105a are provided at equal intervals in the circumferential direction of the frame 105. Further, each frame groove 105a is continuously provided along the axial direction of the frame 105. The axial direction of the frame 105 is a direction parallel to the stacking direction of the iron core pieces 21.

The plurality of bending portions 23 between the yokes are arranged in two rows along the stacking direction of the iron core pieces 21 at the center of the back yoke portion 21B in the width direction. Each frame groove 105a allows all the yoke-to-yoke bent portions 23 in the corresponding divided laminated iron core 2 to escape. That is, all the bent portions 23 between the yokes in each divided laminated iron core 2 are located in the corresponding frame groove 105a.

The method for manufacturing the stator core 1 in the eighth embodiment includes a step of fixing the frame 105 to a plurality of divided laminated iron cores 2 connected in an annular shape. At this time, the yoke end portion 21Ba of each iron core piece 21 is brought into contact with the frame. Other configurations and manufacturing methods are the same as those in the seventh embodiment.

According to such a configuration and a manufacturing method, it is possible to avoid interference between the plurality of bending portions 23 between the yokes and the frame 105, and it is possible to improve the assembly accuracy.

Embodiment 9.
Next, FIG. 35 is a plan view showing the iron core piece set 20 according to the ninth embodiment of the present invention. FIG. 36 is a plan view showing an enlarged portion A of FIG. 35. FIG. 37 is an enlarged plan view showing a portion B of FIG. 35.

In the ninth embodiment, only one yoke connecting portion 207 is provided between the two adjacent back yoke portions 21B. Further, only one teeth connecting portion 208 is provided between the two adjacent teeth portions 21T.

Further, in the iron core piece set 20, at least two teeth connecting portions 208 adjacent to each other in the connecting direction of the iron core pieces 21 are provided at different positions in the width direction of the teeth portions 21T. Further, in the iron core piece set 20, at least two yoke connecting portions 207 adjacent to each other in the connecting direction of the iron core piece 21 are provided at different positions in the width direction of the back yoke portion 21B.

The width direction of the teeth portion 21T and the width direction of the back yoke portion 21B are directions perpendicular to the connecting direction of the iron core pieces 21, that is, the vertical direction in FIG. 35.

For example, the seven iron core pieces 21 shown in FIG. 35 are designated as the first to seventh iron core pieces in order from the left. The yoke connecting portion 207 between the first iron core piece and the second iron core piece is provided on one side of the center of the back yoke portion 21B in the width direction, that is, on the upper side of FIG. 35. On the other hand, the yoke connecting portion 207 between the third iron core piece and the fourth iron core piece is provided on the other side of the center of the back yoke portion 21B in the width direction, that is, on the lower side of FIG. 35. ing.

Further, the teeth connecting portion 208 between the second iron core piece and the third iron core piece is provided on one side with respect to the center in the width direction of the teeth portion 21T. On the other hand, the teeth connecting portion 208 between the fourth iron core piece and the fifth iron core piece is provided on the other side with respect to the center in the width direction of the teeth portion 21T. Further, the teeth connecting portion 208 between the sixth iron core piece and the seventh iron core piece is provided on one side with respect to the center in the width direction of the teeth portion 21T.

In the divided laminated iron core 2 formed by such an iron core piece set 20, at least one set of two tooth-to-teeth bent portions 22 adjacent to each other in the laminating direction are provided at different positions in the moving direction of the rotor 102. There is.

Further, at least one set of two yoke-bending portions 23 adjacent to each other in the stacking direction are provided so as to be displaced from each other at different positions in the moving direction of the rotor 102. Other configurations and manufacturing methods are the same as those of the seventh or eighth embodiment.

According to such a configuration and a manufacturing method, it is possible to prevent the bent portions 22 between the teeth from overlapping each other in the stacking direction. Therefore, even when the bent portion 22 between the teeth has a bulge in the stacking direction of the iron core pieces 21, the gap between the iron core pieces 21 can be suppressed and the shape of the divided laminated iron core 2 can be stabilized.

Similarly, it is possible to prevent the bent portions 23 between the yokes from overlapping each other in the stacking direction. Therefore, even when the bent portion 23 between the yokes bulges in the stacking direction of the iron core pieces 21, the gap between the iron core pieces 21 can be suppressed and the shape of the divided laminated iron core 2 can be stabilized.

It is desirable that all two adjacent tooth connecting portions 208 are provided at different positions in the width direction of the teeth portions 21T. For example, it is desirable to alternately arrange the teeth connecting portions 208 on one side and the other side of the center in the width direction of the teeth portions 21T from one end to the other end of the iron core piece set 20.

Further, it is desirable that all two adjacent yoke connecting portions 207 are provided at different positions in the width direction of the back yoke portion 21B. For example, it is desirable to alternately arrange the yoke connecting portions 207 on one side and the other side of the center in the width direction of the back yoke portion 21B from one end to the other end of the iron core piece set 20.

Further, in the above example, the yoke connecting portions 207 are distributed and arranged at two locations in the width direction of the back yoke portion 21B, but may be dispersed and arranged at three or more locations. Similarly, the teeth connecting portions 208 may be dispersedly arranged at three or more locations in the width direction of the teeth portions 21T.

Further, two or more yoke connecting portions 207 may be provided between two adjacent back yoke portions 21B. Also in this case, at least two yoke connecting portions 207 adjacent to each other in the connecting direction of the iron core piece 21 can be arranged at different positions in the width direction of the back yoke portion 21B.

Similarly, two or more teeth connecting portions 208 may be provided between two adjacent teeth portions 21T. Also in this case, at least two teeth connecting portions 208 adjacent to each other in the connecting direction of the iron core piece 21 can be arranged at different positions in the width direction of the teeth portions 21T.

Further, in the eighth embodiment, at least two yoke connecting portions 207 adjacent to each other in the connecting direction of the iron core piece 21 may be arranged at different positions in the width direction of the back yoke portion 21B.

Embodiment 10.
Next, FIG. 38 is a plan view showing the iron core piece set 20 according to the tenth embodiment of the present invention. A plurality of connecting portions 209 are provided between the iron core pieces 21 in the iron core piece set 20. Each connecting portion 209 connects two adjacent iron core pieces 21.

Further, each connecting portion 209 in the iron core piece set 20 is partially provided between the back yoke portions 21B of two adjacent iron core pieces 21. Each back yoke portion 21B in the iron core piece set 20 is separated from the adjacent back yoke portion 21B except for the connecting portion 209.

The back yoke portion 21B of each iron core piece 21 has a back yoke main body 21Bg, a trapezoidal first protrusion 21Bc, a trapezoidal second protrusion 21Bd, a first yoke notch 21Be, and a second yoke notch. It has a portion 21Bf.

The first protruding portion 21Bc protrudes from the back yoke main body 21Bg toward one side in the width direction of the back yoke portion 21B. The second protruding portion 21Bd protrudes from the back yoke main body 21Bg toward the other side in the width direction of the back yoke portion 21B.

The width direction of the back yoke portion 21B is the connecting direction of the iron core pieces 21, and is the direction parallel to the X axis in FIG. 38. The connecting direction of the iron core pieces 21 is the direction in which a plurality of iron core pieces 21 are lined up in the iron core piece set 20.

The first protruding portion 21Bc and the second protruding portion 21Bd are arranged so as to be offset from each other in the protruding direction of the tooth portion 21T. The protruding direction of the teeth portion 21T is a direction in which the teeth portion 21T protrudes from the back yoke portion 21B, and is a direction parallel to the Y axis in FIG. 38.

The first yoke notch 21Be is arranged on the same side as the first protrusion 21Bc in the width direction of the back yoke 21B. Further, the first yoke notch 21Be is adjacent to the first protrusion 21Bc.

Further, the first yoke cutout portion 21Be is located at the same position as the second protruding portion 21Bd in the protruding direction of the teeth portion 21T. Further, the first yoke notch 21Be has a shape into which the second protrusion 21Bd can be fitted.

The second yoke notch 21Bf is arranged on the same side as the second protrusion 21Bd in the width direction of the back yoke portion 21B. Further, the second yoke notch 21Bf is adjacent to the second protruding portion 21Bd.

Further, the second yoke notch 21Bf is located at the same position as the first protruding portion 21Bc in the protruding direction of the teeth portion 21T. Further, the second yoke notch 21Bf has a shape into which the first protruding portion 21Bc can be fitted.

In the iron core piece set 20, the two adjacent iron core pieces 21 have a symmetrical shape with the connecting portion 209 as the center. In the iron core piece set 20, two types of iron core pieces 21 having a symmetrical shape are alternately arranged in the connecting direction of the iron core pieces 21. That is, in the two adjacent iron core pieces 21, one side and the other side in the width direction of the back yoke portion 21B are opposite to each other.

A plurality of connecting portions 209 in the iron core piece set 20 are provided between the first protruding portions 21Bc and between the second protruding portions 21Bd, respectively. The connecting portion 209 on one side in the width direction and the connecting portion 209 on the other side in the width direction of each back yoke portion 21B are provided at different positions in the protruding direction of the teeth portion 21T from the back yoke portion 21B.

Note that FIG. 39 is an enlarged plan view showing the portion C in FIG. 38. Further, FIG. 40 is a plan view showing an enlarged portion D of FIG. 38.

FIG. 41 is a perspective view showing a process of forming the divided laminated iron core 2 by the iron core piece set 20 of FIG. 38. Each iron core piece 21 is bent in different directions at each connecting portion 209 as in the first embodiment. As a result, the plurality of iron core pieces 21 are laminated to form the divided laminated iron core 2. Further, the specific process for forming the divided laminated iron core 2 is the same as in FIG. 32.

Other configurations and manufacturing methods are the same as those in the first embodiment. Such a method for manufacturing the divided laminated iron core 2 is referred to as a horizontal folding method.

FIG. 42 is a plan view showing the stator core 1 of the tenth embodiment. Further, FIG. 43 is an enlarged plan view showing a main part of FIG. 42. The stator core 1 is formed by combining a plurality of divided laminated cores 2 in an annular shape.

By bending each core piece set 20 at a plurality of connecting portions 209, a plurality of bent portions 24 are formed in each divided laminated iron core 2. Each bent portion 24 is partially provided at both ends of the back yoke portion 21B in the moving direction of the rotor 102 with respect to the stator 101, that is, in the rotating direction.

In the stator core 1, a second protrusion 21Bd of the iron core piece 21 adjacent to the stator core 1 in the circumferential direction is fitted to the first yoke notch 21Be of each core piece 21. Further, the first protruding portion 21Bc of the iron core piece 21 adjacent in the circumferential direction of the stator core 1 is fitted to the second yoke notch 21Bf of each iron core piece 21.

The first protruding portion 21Bc and the second protruding portion 21Bd also serve as a convex portion. The first yoke notch 21Be and the second yoke notch 21Bf also serve as a fitting recess.

In each core piece 21, the first protrusion 21Bc and the second protrusion 21Bd are provided at different positions in the radial direction of the stator core 1.

A gap 110 is provided between each bent portion 24 and the back yoke portion 21B of the adjacent split laminated iron core 2.

In such a configuration and manufacturing method of the tenth embodiment, each connecting portion 209 in the iron core piece set 20 is partially provided between two adjacent back yoke portions 21B. Therefore, each bent portion 24 can be made smaller.

Further, each iron core piece 21 is provided with a first protruding portion 21Bc, a second protruding portion 21Bd, a first yoke notch 21Be, and a second yoke notch 21Bf. Therefore, positioning between the divided laminated iron cores 2 can be easily performed.

In addition, the distance between the centers of two adjacent iron core pieces 21 in the iron core piece set 20 can be increased. Thereby, the two iron core piece sets 20 can be easily arranged on the steel plate sheet 200.

Moreover, the same effect as that of the first embodiment can be obtained.

Further, each bent portion 24 is located in the first yoke notch 21Be or the second yoke notch 21Bf. Therefore, a gap 110 can be provided between each bent portion 24 and the adjacent divided laminated iron core 2. That is, the plurality of bent portions 24 do not hit the adjacent divided laminated iron cores 2. As a result, the shape of the stator core 1 is prevented from collapsing, and the shape accuracy of the stator core 1 can be improved.

Also in the first, third, and sixth embodiments, each connecting portion in each core piece set is partially provided between the back yoke portions of two adjacent iron core pieces. Then, each back yoke portion in each iron core piece set is separated from the adjacent back yoke portion except for the connecting portion.

Further, as shown in FIG. 11, the iron core piece 21 of the third embodiment may also be provided with a first protruding portion, a second protruding portion, a first yoke notch, and a second yoke notch. can.

FIG. 44 is a plan view showing a modified example of the stator core 1 of the tenth embodiment. Further, FIG. 45 is a plan view showing the iron core piece 21 of FIG. 44. In this modification, the shape of the second protrusion 21Bd and the shape of the first yoke notch 21Be are semicircular, respectively.

The shape of the first protrusion 21Bc and the shape of the second protrusion 21Bd are not limited to the shapes shown in FIGS. 38 and 45. Similarly, the shape of the first yoke notch 21Be and the shape of the second yoke notch 21Bf are not limited to the shapes shown in FIGS. 38 and 45.

FIG. 46 is a plan view showing a modified example of the stator core 1 of the third embodiment. Further, FIG. 47 is a plan view showing the iron core piece 21 of FIG. 46. In this modification, the shape of the convex portion 25 and the shape of the fitting concave portion 26 are each rectangular.

The shape of the convex portion 25 and the shape of the fitting concave portion 26 are not limited to the semicircular shape and the rectangular shape.

Embodiment 11.
Next, FIG. 48 is a plan view showing the two iron core piece sets 20 according to the eleventh embodiment of the present invention, and shows the layout of the two iron core piece sets 20 with respect to the steel plate sheet 600. In the steel plate sheet 600, two iron core piece sets 20 are arranged so as to mesh with each other's teeth portions 21T. That is, as shown in FIG. 48, two iron core piece sets 20 are punched out from the steel plate sheet 600.

The shape of each iron core piece 21 in each iron core piece set 20 is the same as that of the tenth embodiment. One of the two iron core piece sets 20 arranged on the steel plate sheet 600 is used as the first iron core piece set, and the other is referred to as the second iron core piece set. Each tooth portion 21T in the first iron core piece set is arranged next to the back yoke portion 21B in the second iron core piece set. Further, each tooth portion 21T in the second iron core piece set is arranged next to the back yoke portion 21B in the first iron core piece set.

Further, each tooth portion 21T in the first iron core piece set is arranged between two adjacent back yoke portions 21B in the second iron core piece set. Further, each tooth portion 21T in the second iron core piece set is arranged between two adjacent back yoke portions 21B in the first iron core piece set.

The distance between two adjacent connecting portions 209 in the first core piece set is larger than the maximum width dimension of the back yoke portion 21B in the portion adjacent to the teeth portion 21T of the second core piece set. The distance between two adjacent connecting portions 209 in the second core piece set is larger than the maximum width dimension of the back yoke portion 21B in the portion adjacent to the teeth portion 21T of the first core piece set.

In FIG. 48, the distance between two adjacent connecting portions 209 is L1 + L2. L1 is the distance from the center line in the width direction of the iron core piece 21 to one connecting portion 209. L2 is the distance from the center line in the width direction of the iron core piece 21 to the other connecting portion 209. L2 has the same or substantially the same size as L1.

Further, the maximum width dimension of the back yoke portion 21B in the portion adjacent to the teeth portion 21T is W1. Therefore, L1 + L2> W1 holds.

Further, the distance between the two adjacent connecting portions 209 in the first iron core piece set is the maximum width dimension of the back yoke portion 21B in the portion adjacent to the teeth portion 21T of the second iron core piece set and the maximum width of the teeth portion 21T. It is larger than the sum of the large dimensions.

Further, the distance between the two adjacent connecting portions 209 in the second iron core piece set is the maximum width dimension of the back yoke portion 21B in the portion adjacent to the teeth portion 21T of the first iron core piece set and the maximum width of the teeth portion 21T. It is larger than the sum of the large dimensions.

In this example, the maximum width dimension of the tooth portion 21T is the width dimension of the tooth tip portion 21Ta. In FIG. 48, the width dimension of the tooth tip portion 21Ta is W2. Therefore, L1 + L2> W1 + W2 holds.

Further, in FIG. 48, θ1 is an angle formed by both end faces in the width direction of the back yoke main body 21Bg. When a plurality of divided laminated iron cores 2 are arranged in an annular shape, the back yoke main body 21Bg is in contact with the back yoke main body 21Bg of the adjacent iron core pieces 21.

Therefore, θ1 is 360 degrees / N. N is the total number of teeth laminated portions in the stator core 1. The teeth laminated portion is a portion in which all the teeth portions 21T are laminated in each divided laminated iron core 2. As in FIG. 27, assuming N = 48, θ1 is 7.5 degrees.

Further, in FIG. 48, two straight lines along both end faces in the width direction of the back yoke main body 21Bg are extended toward the teeth portion 21T, and the point where the two straight lines intersect is set as the center point. However, the center point is not shown in FIG. In the stator core 1, the center point coincides with the axial center of the stator core 1. Further, in the rotary electric machine, the center point coincides with the rotation center of the rotor 102.

In FIG. 48, θ2 is an angle formed by a straight line connecting the center point and the tip of the first protrusion 21Bc and a straight line connecting the center point and the tip of the second protrusion 21Bd. Further, θ2 corresponds to the length of L1 + L2. θ1 is smaller than θ2.

In each core piece set 20, all the connecting portions 209 are parallel to each other and parallel to the center line in the width direction of the core piece 21. That is, all the connecting portions 209 are bent along a straight line parallel to the center line in the width direction of the iron core piece 21.

The steel plate sheet 600 is provided with a plurality of pilot holes 601 for feeding the steel plate sheet 600. The shape of each pilot hole 601 is circular. Further, each pilot hole 601 is provided in a region other than the region of the iron core piece set 20 in the steel plate sheet 600. The method for manufacturing the stator core 1 of the eleventh embodiment includes a step of providing a plurality of pilot holes 601 in the steel plate sheet 600.

The feed direction of the steel sheet sheet 600 is a direction parallel to the X axis of FIG. 48. The direction perpendicular to the feeding direction of the steel plate sheet 600 is defined as the width direction of the steel plate sheet 600. The plurality of pilot holes 601 are provided in the outer region of the connecting portion 209 in the width direction of the steel sheet sheet 600 and in the region between the teeth portion 21T and the connecting portion 209.

Further, a plurality of pilot holes 601 are provided on both sides of the steel plate sheet 600 with respect to the center in the width direction. Further, the plurality of pilot holes 601 are provided so as to be evenly distributed on both sides with respect to the center in the width direction of the steel sheet sheet 600.

When an arbitrary shape is extracted from the steel sheet sheet 600, the steel sheet sheet 600 is moved by the feed length, that is, the feed pitch, by using a feed device (not shown) to perform processing. At this time, the variation in the feed pitch affects the accuracy of the product.

The pilot hole 601 is used for the purpose of correcting the feed error immediately before machining. Specifically, the feed error is corrected by inserting a pilot punch (not shown) into the pilot hole 601. The pilot punch is a pointed shaft. As a result, it is possible to suppress the positional deviation between the steel plate sheet 600 and the press die (not shown).

Therefore, before punching the iron core piece set 20, a plurality of pilot holes 601 are punched out from the steel plate sheet 600 in advance. After that, the two iron core piece sets 20 are punched out at the same time or one by one while performing positioning using the pilot hole 601 as described above. Other configurations and manufacturing methods are the same as those in the tenth embodiment.

In such a configuration and manufacturing method, since L1 + L2> W1, the width dimension of the steel sheet sheet 600 can be made smaller than the layout shown in FIG. Further, since L1 + L2> W1 + W2, each tooth portion 21T in each iron core piece set 20 can be arranged next to the back yoke portion 21B in the iron core piece set 20 arranged in mesh with each other.

Therefore, the width dimension of the steel sheet sheet 600 can be further reduced, and the area of the unnecessary portion 8b can be reduced. As a result, the material yield can be improved and the material cost can be reduced.

Further, each iron core piece 21 is provided with a first protruding portion 21Bc, a second protruding portion 21Bd, a first yoke notch 21Be, and a second yoke notch 21Bf. Therefore, θ1 <θ2 can be set. As a result, the arrangement pitch of the plurality of iron core pieces 21 in each core piece set 20 can be increased as compared with the case of θ1 = θ2. Therefore, the width dimension of the steel sheet sheet 600 can be further reduced, and the area of the unnecessary portion 8b can be reduced.

Further, if L1 ≠ L2, there may be two types of tools used for bending. On the other hand, in the present embodiment, L1 = L2 or L1≈L2, so that the tool shape of the device used for bending can be unified.

Further, all the connecting portions 209 are bent along straight lines parallel to each other. As a result, it is possible to suppress the positional deviation between the iron core pieces 21 adjacent to each other in the stacking direction.

Further, since all the teeth portions 21T can be punched out by arranging them in parallel, all the teeth portions 21T can be punched out while maintaining a constant angle including 0 degrees with respect to the rolling direction of the steel sheet sheet 600. As a result, it is possible to suppress variations in the magnetic characteristics of each iron core piece 21 with respect to the rolling direction of the steel plate sheet 600, and it is possible to reduce the torque pulsation of the rotary electric machine.

Further, since the plurality of pilot holes 601 are provided in the unnecessary portion 8b of the steel sheet sheet 600, it is possible to prevent an increase in the amount of material used.

Further, since the iron core piece 21 has only two types having a symmetrical shape, only two types of press dies are required for punching the iron core piece 21.

Further, each iron core piece 21 is cut out in a state of being connected to the adjacent iron core piece 21. Therefore, it is not necessary to secure a distance between the adjacent iron core pieces 21 of the steel plate sheet 600, and from this point as well, the area of the unnecessary portion 8b can be reduced, and the material yield can be improved.

Further, since the two types of iron core pieces 21 are alternately connected, the bending pitch can be easily set. The bending pitch corresponds to L1 + L2.

Further, when connecting the plurality of divided laminated iron cores 2, the first protruding portion 21Bc is fitted into the second yoke notch 21Bf, and the second protruding portion 21Bd is fitted into the first yoke notch 21Be. .. Therefore, when a plurality of divided laminated iron cores 2 are arranged side by side, it is possible to easily detect an error in the orientation of the divided laminated iron cores 2.

Here, the arrows φ1 and the arrows φ2 in FIG. 48 indicate the flow of the main magnetic flux flowing through each iron core piece 21 when incorporated in the rotary electric machine. As shown in FIG. 48, the magnetic flux flows in the portion of the back yoke portion 21B close to the teeth portion 21T.

On the other hand, in the present embodiment, each connecting portion 209 is provided in a portion of the back yoke portion 21B far from the teeth portion 21T. Further, as shown in FIG. 43, a gap 110 is provided between each bent portion 24 and the back yoke portion 21B of the adjacent split laminated iron core 2.

As described above, the adjacent back yoke portions 21B are in contact with each other at a portion where the magnetic flux easily passes, and a gap 110 is provided at the portion where the magnetic flux is difficult to pass. As a result, the magnetic loss can be suppressed and the efficiency of the rotary electric machine can be improved.

The shape of the pilot hole 601 is not limited to a circle, and may be, for example, a rectangle or a shape that follows the shape of the unnecessary portion 8b.

Further, the position and number of the pilot holes 601 are not limited to the example of FIG. 48.

FIG. 49 is a plan view showing a first modification of the eleventh embodiment. In this example, the shape of the first protruding portion 21Bc and the shape of the second protruding portion 21Bd are rectangular, respectively.

FIG. 50 is a plan view showing a second modification of the eleventh embodiment. In this example, the shape of the first protrusion 21Bc is an elongated rectangle. Further, the shape of the second protruding portion 21Bd is semi-circular.

In this way, the shape of the first protruding portion 21Bc and the shape of the second protruding portion 21Bd can be changed, respectively. Along with this, the shape of the first yoke notch 21Be and the shape of the second yoke notch 21Bf can also be changed. In addition, in FIG. 49 and FIG. 50, the pilot hole 601 is omitted.

FIG. 51 is a plan view showing a third modification of the eleventh embodiment. In this example, the maximum width dimension of the teeth portion 21T is not the width dimension W2 of the teeth tip portion 21Ta, but the width dimension W3 of the portion of the teeth portion 21T adjacent to the back yoke portion 21B.

Further, each tooth portion 21T in each iron core piece set 20 is arranged next to the tooth portion 21T in the iron core piece set 20 which is arranged in mesh with each other.

FIG. 52 is a plan view showing a fourth modification of the eleventh embodiment. In this example, each tooth portion 21T in each iron core piece set 20 is arranged next to the tooth portion 21T in the iron core piece set 20 which is arranged in mesh with each other.

Further, a circular punch hole 602 is provided in the back yoke portion 21B of some of the iron core pieces 21. The punching hole 602 is provided at the end of the back yoke portion 21B on the opposite side of the teeth portion 21T. In FIG. 52, the pilot hole 601 is omitted.

In such a configuration, since the hole 602 is provided in a part of the iron core pieces 21, the weight of the divided laminated iron core 2 can be reduced.

It is also possible to carry out the above-described embodiments 1 to 11 in combination as appropriate.

The present invention can also be applied to an outer rotor type rotary electric machine in which the rotor is arranged outside the stator.

Further, the iron core pieces 21 of the first to eleventh embodiments are made of an electromagnetic steel sheet. However, the material of the iron core piece 21 is not limited to the electromagnetic steel sheet.

Further, in the first to eleventh embodiments, the rotary electric machine is shown as the electric machine, but the present invention can be applied to an electric machine other than the rotary electric machine, for example, a linear motor.

FIG. 53 is a perspective view showing an example of a linear motor to which the present invention is applied. A linear motor as an electric machine has a linear stator 111 which is a field magnet and a pair of movers 112 which are armatures. Note that FIG. 53 shows only a partial configuration of the stator 111 and the mover 112 in order to facilitate understanding of the configuration.

The pair of movers 112 face each other with the stator 111 interposed therebetween. A gap is provided between the pair of movers 112 and the stator 111, respectively. The mover 112 is movable with respect to the stator 111 in the Y-axis direction of FIG. 53.

Each mover 112 has a plurality of split laminated iron cores 113 and a plurality of armature windings 114. The divided laminated iron cores 2 of the first to fifth and 7 to 11 embodiments are combined in an annular shape, but in the linear motor, a plurality of divided laminated iron cores 113 are linearly combined. Instead of linearly combining the plurality of divided laminated iron cores 113, it is also possible to use the same linear laminated iron core as in the sixth embodiment.

The configuration and manufacturing method of each divided laminated iron core 113 are the same as those of any one of the first to fifth and seventh to eleventh embodiments. Each armature winding 114 is wound around a teeth laminated portion of a corresponding split laminated iron core 113.

Even with such a linear motor, the effect of the split laminated iron core as described above can be obtained.

1 Stator core (armature core), 2-4 split laminated core, 2a tooth recess, 2b yoke recess, 3A two-split laminated core, 5 linear laminated core, 8 unnecessary parts, 20 core piece set, 20a between yokes Slit, 20b inter-tooth slit, 21 armature piece, 21T tooth part, 21Ta tooth tip part, 21B back yoke part, 21Ba yoke end part, 21Bc first protrusion, 21Bd second protrusion, 21Be first yoke notch 21Bf 2nd yoke notch, 21Bg back yoke body, 22 tooth-bending part, 23 yoke-bending part, 25 convex part, 26 fitting recess, 30-split core piece set, 31 2-split core piece, 40 core One set, 41 iron core piece, 42, 43 side end forming part, 50 series of iron core pieces, 50a iron core piece set, 101 stator (armature), 102 rotor (field), 104 voids, 105 frame, 105a frame Groove, 110 gap, 111 stator (field), 112 mover (armature), 113 split laminated iron core, 200, 300, 400, 500 steel plate sheet, 201-203, 205, 206, 301, 302, 401- 403,501 connecting part, 207 yoke connecting part, 208 teeth connecting part, 502 iron core piece notch.

Claims (29)

A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a connecting portion connecting the plurality of iron core pieces is each of the iron core pieces. The process of cutting out the iron core piece set provided between them from the steel plate sheet,
The cut out iron core piece set is bent so that one surface of each adjacent iron core piece adjacent to each other at each connection portion faces each other, and the iron core pieces in the iron core piece set are laminated to form a divided laminated iron core. Has a process to do
Each of the connecting portions in the core piece set is partially provided between the back yoke portions of two adjacent iron core pieces.
A method for manufacturing an armature core in which each of the back yoke portions in the iron core piece set is separated from the adjacent back yoke portion in a portion other than the connecting portion. The method for manufacturing an armature core according to claim 1, wherein a convex portion and a fitting concave portion that fits the convex portion are formed in the back yoke portion of each of the iron core pieces. The method for manufacturing an armature core according to claim 1 or 2, wherein a plurality of sets of iron core pieces are arranged on the steel plate sheet so that the teeth portions face each other and are alternately meshed with each other. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the connecting portions in the core piece set is partially provided between the back yoke portions of two adjacent iron core pieces.
Each of the back yoke portions in the iron core piece set is separated from the adjacent back yoke portion in a portion other than the connecting portion.
A plurality of the iron core piece sets are arranged on the steel plate sheet so as to face each other and mesh with each other in a staggered manner.
When one of the two sets of iron core pieces arranged on the steel plate sheet is used as the first set of iron core pieces and the other is used as the second set of iron core pieces.
Each of the teeth portions in the first iron core piece set is arranged next to the back yoke portion in the second iron core piece set.
A method for manufacturing an armature core in which each of the teeth portions in the second iron core piece set is arranged next to the back yoke portion in the first iron core piece set. 4. The fourth aspect of the present invention, wherein the distance between two adjacent connecting portions in the first iron core piece set is larger than the maximum width dimension of the back yoke portion in the portion adjacent to the teeth portion of the second iron core piece set. How to make an armature core. The distance between the two adjacent connecting portions in the first iron core piece set is the maximum width dimension of the back yoke portion in the portion adjacent to the teeth portion of the second iron core piece set and the maximum width of the teeth portion. The method for manufacturing an armature core according to claim 5, which is larger than the sum of the large dimensions. Further having a step of providing a plurality of pilot holes for feeding the steel plate sheet in a region other than the region of the iron core piece set in the steel plate sheet.
When the direction perpendicular to the feed direction of the steel plate sheet is the width direction of the steel plate sheet,
The plurality of pilot holes are provided in at least one of a region outside the connecting portion in the width direction of the steel sheet sheet and a region between the teeth portion and the connecting portion. The method for manufacturing an armature core according to any one of claims 3 to 6, which is provided on both sides of the center of the steel sheet sheet in the width direction. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a connecting portion connecting the plurality of iron core pieces is each of the iron core pieces. The process of cutting out the iron core piece set provided between them from the steel plate sheet,
The cut-out iron core piece set is bent so that one surface of each adjacent iron core piece adjacent to each other at each connection portion faces each other, and the iron core pieces in the iron core piece set are laminated to form a divided laminated iron core. Has a process to do
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
A method for manufacturing an armature core in which each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
Each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion.
A slit between the teeth and two teeth connecting portions are provided between the tip of each tooth in the iron core piece set and the tip of the adjacent teeth.
Each of the teeth-to-teeth slits is provided between the two corresponding teeth-to-teeth connecting portions.
In the step of forming the divided laminated iron core,
By bending the plurality of teeth connecting portions, the plurality of bent portions between the teeth are formed in a state of being aligned in two rows along the stacking direction of the iron core pieces.
A method for manufacturing an armature core in which a tooth recess is formed between two rows of bent portions between the plurality of teeth. Each yoke connecting portion in the iron core piece set is partially provided between two adjacent yoke ends.
The method for manufacturing an armature core according to claim 8, wherein each back yoke portion in the iron core piece set is a portion other than the yoke connecting portion and is separated from the adjacent back yoke portion. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
Each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion.
Each yoke connecting portion in the iron core piece set is partially provided between two adjacent yoke ends.
Each of the back yoke portions in the iron core piece set is a portion other than the yoke connecting portion and is separated from the adjacent back yoke portion.
A slit between the yokes and two yoke connecting portions are provided between each yoke end portion in the iron core piece set and the adjacent yoke end portion.
Each of the yoke slits is provided between two corresponding yoke connecting portions.
In the step of forming the divided laminated iron core,
By bending the plurality of yoke connecting portions, the plurality of bent portions between the yokes are formed in a state of being aligned in two rows along the stacking direction of the iron core pieces.
A method for manufacturing an armature core in which a yoke recess is formed between two rows of bent portions between the plurality of yokes. In the iron core piece set, at least two teeth connecting portions adjacent to each other in the connecting direction of the iron core pieces are provided at different positions in the width direction of the teeth portions.
The armature core according to claim 8, wherein at least two yoke connecting portions adjacent to each other in the connecting direction of the iron core pieces are provided at different positions in the width direction of the back yoke portion in the iron core piece set. Method. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
Each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion.
Side end forming portions constituting the side end portions of the back yoke portion are provided on both sides of the tooth portion of each of the iron core pieces.
One end side of each side end forming portion is connected to the iron core piece by a connecting portion provided at the base of the tooth portion.
The other end of each side end forming portion is a free end.
The step of forming the divided laminated iron core is
After laminating the iron core pieces, the step of rotating the other end side of each side end forming portion toward the back yoke portion with the connection portion as the center and moving the other end side to both side portions of the back yoke portion is included. Mu armature iron core manufacturing method. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
Each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion.
The iron core piece set is
Each of the above-mentioned iron core pieces is divided into two equal parts by a straight line extending in the radial direction.
The pair of divided core pieces are arranged on the steel plate sheet so as to be meshed with each other with the divided linear ends of the divided iron core pieces facing outward.
The step of forming the divided laminated iron core is
An armature core including a step of laminating each of the two-divided core pieces to form a pair of two-divided laminated cores and joining each side surface of the pair of two-divided laminated cores to form the divided laminated core. Manufacturing method. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the connecting portions in the core piece set is partially provided between the back yoke portions of two adjacent iron core pieces.
Each of the back yoke portions in the iron core piece set is separated from the adjacent back yoke portion in a portion other than the connecting portion.
When one of the two adjacent iron core pieces in the iron core piece set is used as the first iron core piece and the other is used as the second iron core piece.
The step of forming the divided laminated iron core is
The process of fixing and positioning the first iron core piece and
The process of using the connecting portion as a reference for bending and
A step of bending the connecting portion and superimposing the second iron core piece on the first iron core piece,
A method for manufacturing an armature core, comprising a step of releasing the first core piece and pressing the second core piece against the first core piece again. A plurality of iron core pieces each having a back yoke portion and a teeth portion protruding from the back yoke portion are linearly arranged, and a plurality of connecting portions connecting the plurality of iron core pieces are between the iron core pieces. The process of cutting out the iron core piece set provided in the steel plate sheet and
A step of bending the cut out iron core piece set at each of the connecting portions and laminating each of the iron core pieces in the iron core piece set to form a divided laminated iron core.
Have,
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
The plurality of iron core pieces in the iron core piece set are arranged so as to alternately abut the yoke ends and the tooth tips.
The plurality of connecting portions have a plurality of yoke connecting portions and a plurality of teeth connecting portions.
Each yoke connecting portion in the iron core piece set is provided between two adjacent yoke ends.
Each of the teeth connecting portions in the iron core piece set is partially provided between two adjacent tooth tips.
Each of the teeth portions in the iron core piece set is separated from the adjacent teeth portions in a portion other than the teeth connecting portion.
When one of the two adjacent iron core pieces in the iron core piece set is used as the first iron core piece and the other is used as the second iron core piece.
The step of forming the divided laminated iron core is
The process of fixing and positioning the first iron core piece and
The process of using the connecting portion as a reference for bending and
A step of bending the connecting portion and superimposing the second iron core piece on the first iron core piece,
A step of releasing the first iron core piece and pressing the second iron core piece against the first iron core piece again.
How to manufacture an armature core that has. A method for manufacturing an electric machine, which comprises the method for manufacturing an armature core according to any one of claims 1 to 16. An armature having an armature and a field that faces the armature through a gap and moves relative to the armature.
The armature core has a plurality of divided laminated cores arranged along the moving direction of the field.
Each of the divided laminated iron cores is configured by laminating a plurality of iron core pieces.
Each of the iron core pieces has a back yoke portion and a teeth portion protruding from the back yoke portion to the field side.
Each of the divided laminated iron cores is provided with a plurality of bent portions that are connected to each other of the iron core pieces adjacent to each other in the laminating direction and bent so that one surface of each of the adjacent iron core pieces faces each other . ,
Each of the bent portions is an electric machine partially provided at an end portion of the back yoke portion in the moving direction of the field. The electric machine according to claim 18, wherein a gap is provided between each of the bent portions and the back yoke portion of the adjacent divided laminated iron core. The back yoke portion of each of the iron core pieces includes a back yoke main body, a first protruding portion protruding from the back yoke main body to one side in the width direction of the back yoke portion, and a back yoke portion from the back yoke main body. It has a second protrusion that protrudes to the other side in the width direction, and has a second protrusion.
The electric machine according to claim 18 or 19, wherein the plurality of bent portions are provided between the first protrusions and the second protrusions of the iron core pieces adjacent to each other in the stacking direction. .. The electric machine according to claim 20, wherein the first protruding portion and the second protruding portion of each iron core piece are provided at different positions in the protruding direction of the teeth portion from the back yoke portion. The back yoke main body of each iron core piece has a first yoke notch into which the second protrusion can be fitted and a second yoke notch into which the first protrusion can be fitted. The electric machine according to claim 21 provided. Claim 20 or claim that the distance between the first protrusion and the second protrusion in each iron core piece is larger than the sum of the width dimension of the back yoke body and the maximum width dimension of the teeth portion. Item 21. The electric machine. An armature having an armature and a field that faces the armature through a gap and moves relative to the armature.
The armature core has a plurality of divided laminated cores arranged along the moving direction of the field.
Each of the divided laminated iron cores is configured by laminating a plurality of iron core pieces.
Each of the iron core pieces has a back yoke portion and a teeth portion protruding from the back yoke portion to the field side.
Each of the back yoke portions has a yoke end portion which is an end portion on the opposite side of the teeth portion.
Each of the teeth portions has a teeth tip portion which is an end portion on the opposite side of the back yoke portion.
Each of the divided laminated iron cores is provided with a plurality of yoke-to-yoke-bent portions and a plurality of tooth-to-teeth-bent portions that are connected and bent between the iron core pieces adjacent to each other in the stacking direction.
The bent portion between the yokes is provided at the end of the yoke.
The bent portion between the teeth is an electric machine partially provided at the tip of the teeth. 24. The electric machine according to claim 24, wherein each of the bent portions between the yokes is partially provided at the end portion of the yoke. The plurality of bent portions between the teeth are formed in a state of being aligned in two rows along the stacking direction of the iron core pieces.
The electric machine according to claim 24 or 25, wherein a tooth recess is formed between the two rows of the plurality of bent portions between the teeth. The plurality of yoke-bent portions are formed in a state of being aligned in two rows along the stacking direction of the iron core pieces.
25. The electric machine according to claim 25, wherein a yoke recess is formed between the two rows of the plurality of bending portions between the yokes. At least one set of two bent portions between the teeth adjacent to each other in the stacking direction are provided so as to be offset from each other at different positions in the moving direction of the field.
25. The electric machine according to claim 25, wherein at least one set of two bending portions between the yokes adjacent to each other in the stacking direction are provided at different positions in the moving direction of the field. Further provided with a frame fixed to the armature core and in contact with the yoke end of each piece of the armature.
The electric machine according to any one of claims 24 to 28, wherein the frame is provided with a plurality of frame grooves for allowing the bent portions between the plurality of yokes to escape from each other.

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