JPH05292708A - Manufacture of split type stator - Google Patents

Abstract

PURPOSE:To obtain a split type stator, durability and reliability of which can be ensured, by forming bridging sections at the inner circumferential ends or outer circumferential ends of a plurality of pole piece form sections, cutting the bridging sections among magnetic pole sections after resin molding and manufacturing a core. CONSTITUTION:When an electric rotary machine is manufactured, a plurality of core blank materials 7 are punched from an electromagnetic steel strip, but a plurality of pole piece form sections 70 are arrayed annularly in the core blank materials 7, and the core blank materials 7 have a shape that U-shaped bridging sections 72 are projected among adjacent internal end sections. Each pole piece form section 70 is formed in a T shape and recessed sections 73 are formed to outer end surfaces, and magnetic pole sections 71 are shaped at inner end sections. The core blank materials 7 are laminated while being aligned and charged into a molding die, a synthetic resin material is injected and cylindrical connecting sections are formed to inner circumferential sections while outer surfaces except outer end surfaces are insulated, and the outer-end section recessed sections 73 are filled simultaneously with a synthetic resin and outer end sections are projected and fixed mutually. Sections up to the inner circumferential ends of the magnetic pole sections 71 are cut in the inner circumferential sections and the size is measured, and the bridging sections 72 are removed, thus acquiring a core.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a method for manufacturing a split type stator of a rotary electric machine.

[0002]

2. Description of the Related Art In a rotary electric machine, for example, the actual development 56
As disclosed in Japanese Patent Publication No. 141576/1990, a structure in which a slot is formed on the inner circumference of a stator and a coil wound in advance is wound between the slots by an inserter method has been widely adopted. The child had a problem that the coil winding work was complicated. On the other hand, as disclosed in Japanese Utility Model Laid-Open No. 2-44848, a plurality of pole pieces are arranged in an annular shape, and inner magnetic pole portions thereof are connected by a synthetic resin material or the like to form an iron core, and between the slots of the iron core. There has been proposed a split type stator in which a coil is wound around and then an iron core is fitted into a cylindrical yoke.

In such a split type stator, when a plurality of pole pieces are arranged in an annular shape and the inner magnetic pole portions thereof are connected by a synthetic resin material, the respective pole pieces are separated from each other and their mutual positioning is difficult, How to solve this is an important issue. Therefore, as a method of manufacturing a split type stator, as shown in Japanese Patent Application Laid-Open No. 4-58746, a plurality of pole piece-shaped iron plates are punched out, and an iron core element shape in which pole pieces are connected by bridging portions is used. Several iron plates are punched out, the iron-core-shaped iron plate and the pole-piece-shaped iron plate are superposed, the inner magnetic pole parts are connected with a synthetic resin material, and then the bridging parts are punched to manufacture an iron core. A method of doing so has been proposed.

[0004]

However, in the method of manufacturing the split type stator described in the prior art publication, since it is necessary to punch in the laminating direction of the iron plates when punching the bridging portion, the connection between the inner magnetic pole portions is required. There is a problem in that it is difficult to guarantee durability and reliability because an impact is applied to the part and the connecting part is damaged. Further, since the pole piece-shaped iron plates are different from each other, there is a possibility that the pole piece-shaped iron plates may be displaced with respect to the iron-core-shaped iron plate, and it is necessary to take measures against it. SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing a split type stator in which each pole piece can be accurately positioned and connected in such a situation and durability and reliability can be guaranteed.

[0005]

As a result of intensive studies to solve the above-mentioned problems, the inventors of the present invention have normally secured an air gap on the outer circumference of the rotor in the manufacturing process of the rotor and the stator, and have a concentricity and dimension. Therefore, focusing on the fact that cutting is performed, it was found that the bridging portion between the pole pieces can be simultaneously cut during such cutting, and the present invention was completed. That is, the method for manufacturing the split type stator according to the present invention is described as follows: "A plurality of pole pieces are arranged in an annular shape and inner magnetic pole portions thereof are connected to each other by a synthetic resin material to form an iron core, and the iron core is formed in the outer peripheral slot When manufacturing a split type stator in which winding is applied to and inserted into a cylindrical yoke, a plurality of pole piece shaped portions are arranged in an annular shape and adjacent to the inner peripheral end or outer peripheral end of each pole piece shaped portion. An iron core material having a bridging portion protruding inward from the inner peripheral end or protruding outward from the outer peripheral end is integrally molded between the end portions, and a plurality of iron core raw material is stacked. Insert into a resin mold, connect at least the magnetic poles of each pole piece shape part with a synthetic resin material, and cut the bridging part between the magnetic pole parts of each pole piece shape part to manufacture an iron core The main point is that Here, it is general to insulate between the slot and the winding with insulating paper or the like when winding the coil, but when connecting the magnetic pole portions of each pole piece-shaped portion with a synthetic resin material,
If the outer surface of each pole piece-shaped portion is covered with a synthetic resin material to insulate it, insulating paper or end plates can be omitted. In addition, if the concentricity and roundness of the pole piece tip magnetic poles vary due to the type and thickness of the synthetic resin material and the rotation efficiency fluctuates, the bottom surface of the inner peripheral surface of the cylindrical yoke may change. It is preferable to form a wide fitting recess and fit the outer end of the pole piece into the fitting recess.

[0006]

According to the present invention, the iron core material having the bridging portion projecting inward or outward at the inner peripheral edge or the outer peripheral edge of the pole piece shaped portions arranged in an annular shape is integrally formed and laminated. rear,
Since the bridging part is cut by connecting the magnetic pole parts with synthetic resin, impact does not act on the inner connecting part of the pole piece compared to the punching method, and durability and reliability may be impaired. Absent. In addition, since the iron core element formed by connecting the annular pole piece shape parts with the bridging part is integrally formed and laminated, the pole piece itself and the iron plate that constitutes it are not displaced, Be positioned at.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the specific examples shown in the drawings. 1 to 3 show a split stator manufacturing method according to an embodiment of the present invention, and FIGS. 4 to 8 show a rotating electric machine 1 manufactured by the above method. 4 to 9, in the rotating electric machine 1, the front and rear frames 10 and the cylindrical housing 12 are connected by screws to form a motor outer shell 13, and the motor outer shell 13 has an annular stator 2 and a rotating member. The child 3 is installed inside, and the rotor 3 is the stator 2.
The rotary shaft 30 is loaded into the frame 10 and is rotatably held on the frame 10 by the bearing 11. The stator 2 is configured by fitting an iron core 21 in a cylindrical yoke 20, and the iron core 21 has a slot 2 extending in the axial direction on the outer peripheral side thereof.
2 is formed at every predetermined angle.

Further, the yoke 20 is formed by punching and laminating electromagnetic steel strips and crimping or welding them, and the iron core 21 is formed by arranging a plurality of pole pieces 5 in an annular shape ( 5 (a) and 5 (b)), each pole piece 5 is formed by punching and stacking electromagnetic steel strips. A magnetic pole portion 50 is formed on the inner end side of each of the plurality of pole pieces 5, and a wide end portion 51 is formed on the outer end side to form a substantially T-shape as a whole, and each inner end side magnetic pole portion 50 is formed. Are connected to each other by a holding member 60 made of a synthetic resin material, and an insulating layer 61 is formed by covering the surface of each pole piece 5 with the same synthetic resin material as the holding member 60 except for the outer base end face 52. ing. Further, a recess 53 is formed in the axial direction in the outer base end surface 52 of each of the pole pieces 5, and the recess 53 is formed.
A synthetic resin material is continuously filled in the inside of the pole piece 5 so that the iron plates of the pole piece 5 are connected to each other to prevent the peeling thereof, and the front end portion and the rear end portion of the connecting portion 62 are protruded. A wire drip prevention projection 63 is formed to prevent the winding from slipping during the winding operation (Fig. 6 (a),
(See (b)). On the other hand, fitting recesses 23 are formed on the inner peripheral surface of the cylindrical yoke 20 so as to correspond to the respective pole pieces 5, and both side surfaces of each fitting recess 23 are formed so as to spread toward the bottom.
The outer end portion 51 of the pole piece 5 is fitted into the fitting recess 23 to prevent the pole piece 5 from being displaced inward.

Next, the manufacturing method will be described with reference to FIGS. When manufacturing the rotary electric machine 1, a plurality of iron core material 7 is punched out from the electromagnetic steel strip (see step S1).
As shown in FIG. 2, the iron core material 7 has a plurality of pole piece-shaped portions 70 arranged in an annular shape, and between the adjacent inner end portions of each pole piece-shaped portion 70 is substantially inward from the inner peripheral end thereof. It has a shape in which a U-shaped bridging portion 72 is provided in a protruding manner, and each pole piece-shaped portion 70 has a substantially T shape, and a concave portion 73 is formed on the outer end surface.
Is formed, and a magnetic pole portion 71 that spreads to both sides is formed at the inner end portion. Next, the iron core material 7 is laminated while being aligned, loaded into a molding die (not shown), and a predetermined synthetic resin material is injected, and the laminated iron core material 7 is bridged. A cylindrical connecting portion is formed on the inner peripheral portion including the entangled portion 72, and the outer surface of the laminated iron core material 7 except the outer end surface is covered with a synthetic resin material for insulation, and at the same time continuous with these. By filling the outer end recessed portion 73 with a synthetic resin material and projecting the outer end portion thereof outwardly, and the iron core blanks 7 thus laminated are fixed to each other to form an iron core material (step S2, 3). When the resin molding is completed in this way, the inner peripheral portion of the iron core material is attached to the magnetic pole portion 7.
The iron core 21 can be manufactured by cutting to the inner peripheral end of No. 1 to perform dimensioning and removing the U-shaped bridging portion 72 (see step S4). As a result, each magnetic pole portion 71 is completely separated,
The magnetic characteristics can be secured. The bridging portion 72 may be cut after the assembling step S9 for assembling the iron core and the yoke.
Next, winding is directly performed in each slot 22 of the iron core 21,
The winding is fixed with varnish, and the end portion of the winding is processed.

On the other hand, for the yoke 20, a plurality of yoke blanks 8 are punched out from the electromagnetic steel strip (see step S6).
As shown in FIG. 3, the yoke blank 8 has side surface inversely tapered protrusions 80 formed at predetermined intervals so that the outer ends of the pole pieces 5 of the iron core 21 can be fitted to the inner peripheral end of the yoke blank 8. Have a different shape. The yoke blanks 8 are laminated while being aligned with each other and fixed to each other by crimping (or welding) to manufacture the yoke 20 (see steps S7 and S8). When the iron core 21 and the yoke 20 are manufactured in this manner, the split stator 2 can be manufactured by inserting the iron core 21 into the yoke 20 (see steps 9 and 10). After that, as in the conventional case, the annular stator 2 is provided in the cylindrical housing 12 of the motor outer shell 13.
And the rotor 3 is inserted into the stator 2, the rotary shaft 30 of the rotor 3 is rotatably held on the frame 10 by the bearing 11, and the frame 10 is attached to the front and rear of the cylindrical housing 12. By fixing with screws and further drawing out the coil wiring 41 from the drawing-out hole of the front frame 10, the rotary electric machine 1 as shown in FIG. 8 can be manufactured.

In the method of manufacturing the split type stator of the present embodiment as described above, the inner magnetic pole portion 7 of each pole piece shape portion 70 is formed.
Since the inwardly projecting bridging part 72 is formed between the one and the bridging part 72 is cut after the resin molding, the impact does not act unlike the conventional punching, and the resin material is filled. Since there is no burr due to cutting, and the resin connection part 6
It is possible to prevent breakage of 0, and it is possible to guarantee the durability and reliability of the stator 2. Moreover, the molding work is very easy, mass production is possible, and significant cost reduction can be realized.

In the method of manufacturing the split type stator of this embodiment, the insulating layer 61 made of synthetic resin is formed on the surface of each pole piece 5.
Since the insulating sheet and the end plate as in the conventional case are not required, the winding work can be simplified and the cost can be reduced. Further, in the method of manufacturing the split type stator of the present embodiment, the yoke 20 is formed with the fitting recessed portion 23 having a widened bottom, and the base end portion 51 of the pole piece 5 is fitted into the fitting recessed portion 23. Piece 5 to yoke 20
By firmly fixing it to the inner peripheral surface, the gap between the magnetic pole surface of the stator 2 and the rotor 3 can be reliably prevented from changing, and the reliability of the rotary electric machine 1 can be guaranteed.

[0013]

As described above, according to the method for manufacturing a split type stator according to the present invention, a bridging portion is provided on the inner circumference or the outer circumference of each pole piece at the time of punching an electromagnetic steel strip, and cutting is performed after resin molding. As a result, the pole pieces can be accurately positioned, the manufacturing work can be simplified, the cost can be reduced, and the durability and reliability can be guaranteed.

[Brief description of drawings]

FIG. 1 is a process drawing showing a method of manufacturing a split type stator according to an embodiment of the present invention.

FIG. 2 is a diagram showing an iron core material in the above manufacturing method.

FIG. 3 is a view showing a yoke blank in the above manufacturing method.

FIG. 4 is a perspective view and a front view showing a stator iron core of a rotating electric machine manufactured by the above method.

5A and 5B are a perspective view and a front view showing a pole piece of the iron core.

6A and 6B are a plan view and a side view of an essential part showing an insulating layer in the pole piece.

7A and 7B are a perspective view and a front view showing a stator yoke of a rotating electric machine manufactured by the above method.

FIG. 8 is a cross-sectional configuration diagram showing a rotary electric machine manufactured by the above method.

[Explanation of symbols]

2 split type stator 20 yoke 21 iron core 22 slot 5 pole piece 50 magnetic pole portion 60 holding member 61 insulating layer 7 iron core material 70 pole piece shape portion 71 magnetic pole portion 72 bridging portion

Claims (2)

[Claims] 1. A cylindrical yoke in which a plurality of pole pieces 5 are arranged in an annular shape, and inner magnetic pole portions 50 thereof are connected to each other by a synthetic resin material to form an iron core, and the iron core is wound around its outer peripheral slot. When manufacturing the split type stator formed by inserting into each of the pole pieces, the plurality of pole piece shaped portions are arranged in an annular shape, and the inner circumference end of each pole piece shaped portion or the inner circumference end between the adjacent end portions of the outer circumference end is formed. Iron core material having a bridging part protruding toward the outside or protruding outward from the outer peripheral end is integrally molded, and a plurality of iron core materials are stacked and loaded into a molding die, and synthesized. At least the pole pieces of each pole piece shape are connected by a resin material, and the bridging portion between the pole pieces of each pole piece shape part is cut to manufacture an iron core. Child manufacturing method. 2. The outer surface of each pole piece shape portion is covered with a synthetic resin material to be insulated when connecting the magnetic pole portions of each pole piece shape portion with a synthetic resin material. Method for manufacturing split stator.