JPH0241641A - Manufacture of stator for motor - Google Patents

Abstract

PURPOSE:To improve an yield of a material, and to insert windings easily into the slots of wound cores by punching two rectilinear core blank sections having the same shape from one band plate and molding these sections to the wound cores. CONSTITUTION:Holes 7 are punched zigzag at sections as the nose sections of the teeth of one band plate 8. Teeth 2, face width of which is kept constant and nose sections of which are formed to an arcuate shape, and slots 3 having the same contour shapes as the teeth 2 are punched continuously, thus acquiring two rectilinear core blank shapes 9 mutually having the same shape. The rectilinear core blank sections 9 are molded successively to the arcuate shape while the tooth-slot forming side 9a is directed inward, thus shaping a wound core 1. Strands are wound into each slot 3 of the wound core 1, and windings 4 previously molded to an elliptical form are inserted. The nose sections 5 of teeth and the holes 7 are crushed in the radial direction, and the holes 7 are removed while the nose sections 5 of teeth are deformed in the circumferential direction. The nose sections 5 of teeth is widened, and the clearances of the slot opening sections 6 are narrowed.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a stator for electric motors used in, for example, air-conditioning and air conditioners, automobiles, etc. The present invention relates to a method of manufacturing a stator for an electric motor, in which windings can be easily inserted into slots of the motor.

[Prior Art] Conventional methods for manufacturing stators for electric motors include, for example: ■ In order to improve material yield, stators for electric motors are manufactured by winding and laminating strip-shaped iron core materials in a spiral shape. What we manufacture: ■In order to make it easier to insert the winding wire into the slot of the wound core, the tip of the tooth that forms the slot opening (the tip of the tooth is wider than the root of the tooth) is sloped. (1) A type in which a notch is provided at the tip of the tooth of the wound iron core, and the tooth tip is expanded after the winding wire is inserted into the slot; (2) A notch is provided in the tooth tip of the tooth of the wound iron core, and the tooth tip is expanded after the winding wire is inserted into the slot; Some methods are known, such as one that closes the opening, and one that fills the vicinity of the slot opening with heated foamable magnetic material after the winding wire is inserted into the slot.

In addition, related methods of this type include Japanese Patent Application Laid-open No. 5
5-29241, JP-A-55-49955, and JP-A-55-79660.

JP-A-55-109157, JP-A-577555
1, JP-A No. 57-8024.6, and the like.

[Problems to be Solved by the Invention] The above-mentioned prior art does not give sufficient consideration to improving the material yield and making it easy to insert the winding wire into the slot of the wound core, and the following problems occur. There was a problem.

That is, if the tips of the teeth of the wound core are wider than the roots, there is a risk that the wire surface of the winding may be damaged by the tips when the winding is inserted into the slot. In order to prevent this, not only a special insertion jig is required, but also the alignment accuracy of the throwers 1 to 1 has to be made highly accurate.

On the other hand, in the method of closing the slot opening by bending the tooth tip, the opening is closed in several steps using a bending jig that bends the tooth tip, or in order to close the opening in one step, a total shape is used. In any case, it was not easy to insert the winding wire into the slot, and there was not much consideration given to material yield.

The present invention solves the problems of the prior art described above and provides a method for manufacturing a stator for an electric motor, which has a high material yield and allows easy insertion of windings into slots of a wound core. This is the purpose.

[Means for Solving the Problems] In order to solve the above-mentioned problems, the method of manufacturing a stator for an electric motor according to the present invention has a structure in which the tooth tip has the same width as the tooth root or a width narrower than the tooth root. Then, the teeth and the slots with the same outline shape alternately repeat the above-mentioned shape, and the two linear iron core blanks are made into one strip by making one tooth become the slot of the other. A first step of punching out a plate, and a second step of forming a wound core by forming the linear core material into a spiral shape with the tooth/thrower 1 to forming side facing inside and sequentially stacking these. a third step of welding the core materials together along the axial direction of the wound core at multiple locations on the outer periphery of the wound core; and a fourth step of annealing the wound core after this welding. process and into the slot of this wound core,
A fifth step of inserting a winding wire formed in advance into a predetermined shape and crushing the tips of the teeth of the wound core outward in the radial direction of the wound core narrows the opening of the slot and creates a predetermined shape. and a sixth step of cutting the inner diameter of the stator.

More details are as follows.

The above purpose is to punch out two linear iron core blanks of the same shape from one strip plate to slot 1, with the teeth of one slot being the same as the teeth of the other. ,
This is accomplished by spirally winding and laminating the linear core material to form a wound core, and after inserting the winding wire into the slot, pressing the tips of the teeth radially outward.

[Operation] By punching out two linear core blanks of the same shape from one strip and forming them into a wound core, there is almost no punching waste, and the material yield is significantly increased.

Since the tips of the teeth of the winding core are not wide, the slot opening dimension is sufficiently larger than the outer diameter of the winding, making it easy to insert the winding into the slot, and improving the alignment accuracy of the slot. does not need to be highly accurate.

Since the tips of the teeth are crushed radially outward after the winding is inserted, the tips of the teeth expand in the circumferential direction, the slot openings are pinched, and the winding is completely fixed without coming off.

[Example] Hereinafter, the present invention will be explained by examples.

FIG. 1 is a plan view showing a stator for an electric motor manufactured by a method for manufacturing a stator for an electric motor according to an embodiment of the present invention, and FIG. 2 shows a state in which the first step in this manufacturing method is implemented. FIG. 3 is a schematic front view showing the wound core forming apparatus used for carrying out the second step, FIG. 4 is a view taken along arrow I-1 in FIG. 3, and FIG. , a sectional view showing the tooth tip suppressing device used to implement the sixth step, and FIGS. 6 to 9 show the progress of crushing the tooth tip by the tooth tip suppressing device according to FIG. and n−n in FIG. 5, respectively.
, mm, rv-rv, and v-v are plan views of the main parts as seen from the arrow directions.

First, an overview of the apparatus used to implement this embodiment will be explained.

Press equipment (not shown) used to carry out the first step
■ A punch/die that can drill holes in a staggered pattern at the tip of the tooth of the band plate; With arc-shaped teeth,
It is equipped with a tooth/slot punch/die that can alternately and continuously punch out these teeth and slots having the same outline shape.

As shown in FIGS. 3 and 4, the wound core forming device used to carry out the second step has a tapered tip,
A set of rolling rolls, each rotatable around its axis1.
1.12 and two sheets 1 arranged on the inlet side of the straight core material 9 (this will be explained in the embodiment of the manufacturing method).
A set of entrance guides 13, a set of two exit guides 14 disposed on the exit side, and a rotatable shaft located between these two exit guides 14 for setting the outer diameter of the wound core 1. an outer diameter setting roller 15, and the rolling roll 11. ] 2, and a core metal 16 for winding up the spiral molded body rolled in step 2.

By adjusting the relative angle between the rolling rolls 11 and 12, the gap between the two rolls, and the distance between the outer diameter setting roller 15 and both rolls, a wound core with a desired outer diameter (in other words, a desired number of slots) can be obtained. 1 is obtained.

The tooth tip suppression device used to carry out the sixth step connects a tapered part 19a (the tip is thinner than the stator inner diameter) and this taper part 19a, and adjusts the diameter to the target of the stator inner diameter. A punch 1 having a cylindrical portion 19b equal to the value
9 is arranged concentrically with the hole 18 of the die 17 and movable up and down.

The punch 19 can then be lowered by a press (not shown).

Next, a method of manufacturing a stator for an electric motor according to an embodiment of the present invention will be described using the above-described apparatus.

Referring to FIG. 2, when one strip plate 8 is sent to the press device on a conveyor (not shown) (in the left direction indicated by the arrow in FIG. 2), the tip of the tooth Holes 7 are punched out in a staggered manner using the hole punch and die at locations that will become the parts. This hole 7 becomes a pilot hole, and is fed further to the left, and the tooth/slot punch/die produces a tooth 2 with a constant tooth width and an arcuate tip, and a slot 3 with the same contour shape. are successively punched out to obtain two linear iron core elements 9 having the same shape [this is the first step].

Two straight iron core blanks 9 punched in this way,
9 are each sent to a wound core forming device. To explain one of the sheets (the other sheet is also formed into a wound core from another wound core forming device), the leading part of the sheet is introduced into the space between the rolling rolls 11 and 12 through the entry logite 13. Then, the opposite tooth/slot forming side 9b is rolled by the rolling rolls 11 and 12 in such a manner that the rolling reduction ratio becomes larger closer to the outer edge. As a result, the linear core material 9 is successively formed into an arc shape with the tooth/slot forming side 9a inside. Then, the outer diameter setting roller 15 pushes the back surface of the non-toothed/slot forming side 9b to determine the diameter of the arc, and after one round of forming, the core metal 16 is moved across the rolling rolls 12 under the guidance of the exit guide 14. It is wound around in a spiral. This is done continuously and the layers are sequentially stacked, and at a point of a predetermined length (that is, the length of one wound core), the linear core material 9 is cut with a cutter (not shown).
and one wound core 1 is formed on the core bar 16 [the above is the second step].

At multiple locations on the outer periphery of the wound core 1 (for example, four locations separated by 90° from each other), the core materials are welded (not shown) to each other along the axial direction of the wound core 1. be done. This makes it possible to maintain the axial alignment of the slots 3 [this is the third step].

This wound core 1 is transported to a tunnel furnace (not shown) by a conveyor (not shown), where it is heated to 800'C, 1
Time annealing is performed to remove residual strain [this is the fourth step].

Next, into each slot 3 of this wound core 1, the winding 4, which has been formed into an oval shape by winding a wire, is inserted using an insertion device (not shown). Process.

The wound core 1 into which the winding wire 4 has been inserted is mounted and fixed on a die 17 of a tooth tip suppression device (FIG. 5) so as to be concentric with the hole 18 of the die 17.

When the punch 19 is lowered by the press, the tapered part 19a of the punch 19 touches the tip 5 of the tooth 2 of the wound core 1.
As shown in FIG. 6, the shape of the tooth 2 remains the same as that of the linear core material 9 until it comes into contact with the straight core material 9. When the punch 19 further descends and is pushed into the inside of the wound core 1, the tapered part 19a of the punch 19 comes into contact with the tip 5 of the tooth 2 of the wound core 1, gradually pushing the tip 5 of the tooth 2 outward in the radial direction. It begins to press. Since the hole 7 is bored in the tip 5 of the tooth 2, the tip 5 of the tooth 2 is mainly deformed only in the vicinity of the hole 7, and the deformation does not extend to the base of the tooth 2. In this way, by further pushing the punch 19,
As shown in FIGS. 7 and 8, the tip 5 of the tooth and the hole 7 collapse in the radial direction and the hole disappears, and at the same time, the tip 5 of the tooth
is also deformed in the circumferential direction. Then, the width of the tip 5 of the tooth increases, the gap between the slot opening 6 narrows, and the hole 7 is completely collapsed as shown in FIG. Finished in In addition, the gap between the slot openings 6 becomes narrower than the wire diameter of the winding 4,
The winding 4 is fixed in the slot, and the desired electric motor stator as shown in FIG. 1 is obtained [this is the sixth step].

According to the embodiment described above, there are the following effects.

■When punching out the linear core material 9 from the strip plate 8, the hole 7
The material yield is very high because the part becomes only scraps.

Since rolling is performed when forming the 00-wound core 1, the wound core 1 with a small outer diameter can be easily formed without buckling.

Since the tips 5 of the teeth of the 00-wound core 1 are arcuate, the gap between the slot openings 6 can be made sufficiently larger than the diameter of the winding 4. Therefore, the winding 4 can be easily inserted into the slot 3 without damaging the outer periphery of the winding 4, and
Can be inserted with high density.

(2) Since the tooth width of the tooth 2 is constant from the tooth tip to the tooth base, the winding wire storage space of the slot 3 can be made large.

Therefore, the number of wires in the winding 4 can be increased,
Magnetic force can be increased and motor output can be increased.

(2) Since the hole 7 is provided in the tip 5 of the tooth, it is easy to crush the tip 5 in the radial direction and expand it in the circumferential direction, and also avoids unnecessary deformation in other parts. I have nothing to give.

(2) By making the gap between the slot openings 6 smaller than the wire diameter of the winding 4, the winding 4 will not come out of the slot 3.

(2) Since the tips 5 of the teeth are crushed after the winding 4 is inserted into the slot 3, it is not necessary to increase the alignment accuracy of the winding core 1.

■Since the punch 19 is used to crush the tooth tip 5, the structure of the tooth tip suppressing device is simple.
There are also economical advantages, such as the ability to easily maintain the strength and extend the life of the device.

Note that even if the hole 7 is not provided in the tip 5 of the tooth, the tip 5
can be crushed in the radial direction.

Furthermore, although the tip of the tooth and the base of the thrower l-3 have been shown in the embodiment as being arcuate, they may be straight, for example.

Furthermore, although the wound core 1 of this embodiment was formed by rolling, it may be formed by winding the linear core material 9 around the core metal while applying tension.

Furthermore, the method of the present invention can also be applied to the manufacture of movers for electric motors.

[Effects of the Invention] As described in detail above, the present invention provides a method for manufacturing a stator for an electric motor, which has a high material yield and allows easy insertion of windings into slots of a wound core. be able to.

[Brief explanation of the drawing]

FIG. 1 is a plan view showing a stator for an electric motor manufactured by a method for manufacturing a stator for an electric motor according to an embodiment of the present invention, and FIG. 2 shows a state in which the first step in this manufacturing method is implemented. FIG. 3 is a schematic front view showing the wound core forming apparatus 5 used to carry out the process shown in FIG. 2, and FIG. FIG. 5 is a cross-sectional view showing the tooth tip suppression device used to implement the sixth step, and FIGS. 6 to 9 show the progress of crushing the tooth tip by the tooth tip suppression device according to FIG. nn, m-m, and rv-r in Fig. 5, respectively.
FIG. 1... Wound core 52... Teeth, 3... Slot, 4...
・Windling, 5 ・Tip of tooth, 7 ・Hole, 8 ・Strip plate, 9
Straight iron core material, 11.12... Rolling roll, 19
...Ponchi.

Claims (1)

[Scope of Claims] 1. Two teeth whose tips are the same width as the root or narrower than the root, and slots whose contours are the same as those of the teeth, alternately repeating the above-mentioned shapes. A first step of punching a straight core blank from one strip plate with one tooth serving as a slot on the other; and punching the straight core blank with the tooth/slot forming side facing inside. By forming the materials into a spiral shape and layering them one after another,
a second step of forming a wound core; a third step of welding the core materials together along the axial direction of the wound core at multiple locations on the outer periphery of the wound core; and after this welding. a fourth step of annealing the wound core; a fifth step of inserting a winding wire formed into a predetermined shape into the slot of the wound iron core; A method for manufacturing a stator for an electric motor, comprising the step of narrowing the opening of the slot and finishing the stator to a predetermined inner diameter by crushing the stator outward in the radial direction. 2. The method of manufacturing a stator for an electric motor according to claim 1, wherein the strip in the first step is a strip in which holes are pre-drilled at locations that will become the tips of the teeth. 3. The method of manufacturing a stator for an electric motor according to claim 1, wherein the shape of the teeth in the first step is such that the tooth tip has the same width as the tooth root. 4. The spiral forming in the second step is a rolling process in which the opposite tooth/slot forming side of the linear core material is rolled with the rolling reduction increasing as it approaches the outer edge. The method of manufacturing a stator for an electric motor according to claim 1, characterized in that: 5. The sixth step is to use a punch having a tapered part whose tip is tapered to be thinner than the inner diameter of the stator, and a cylindrical part connected to this tapered part and having a diameter equal to the inner diameter of the stator. 2. A stator for an electric motor according to claim 1, characterized in that the step of pushing the punch into the inside of the wound core from the tip side with the center axis of the punch aligned with the center axis of the wound core. Production method.