JPH0622508A - Manufacture of stator core of motor - Google Patents

Abstract

PURPOSE:To smoothen a series of manufacturing process including lamination and fixation of a stator core and coil winding work for forming a york core and magnetic pole core in division method. CONSTITUTION:Manufacture of stator core comprising a process of forming projections (d) and (e) for entangled caulking of a yoke segment (a) and a magnetic pole segment (b); a process of punching the yoke segment (a) after reconnection with the magnetic pole segment (b); a process of forming the yoke core and the magnetic pole core by laminating and fixing the yoke segment (a) and magnetic pole segment (b) in a state where they are jointed together; a process of performing insulation treatment by mold-forming a resin for the magnetic pole core; and a process of separating the magnetic pole core, which is insulation-treated, from the yoke core and the magnetic pole core is wound and fitted and attached to the yoke core.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a stator core of a small electric motor used for fan heaters, ventilation fans and the like.

[0002]

2. Description of the Related Art In recent years, in mass production of small electric motors,
For example, there is a strong demand for facilitating a series of operations in the manufacturing process of the stator core, such as insulation treatment during winding of the stator core and winding of a coil conductor around the stator core.

In a conventional method of manufacturing a stator core of this type of electric motor, as shown in FIG. 17, an iron core plate 3 made of a silicon steel plate in which a yoke piece 1 and a pole piece 2 are integrally punched out.
The stator core 4 was manufactured by laminating and fixing the required number of sheets. When winding a coil (not shown) around the stator core 4, the yoke piece 1 and the magnetic pole piece 2 are used.
Are integrally formed, and the magnetic pole piece 2 is formed so as to protrude toward the center of the stator core 4, so that the winding method of the stator core 4 is necessarily the insert method. I don't get. Therefore, the outer peripheral length of the coil portion wound around the magnetic pole piece 2 becomes long, and this extra portion protrudes outward from both end surfaces of the stator core 4, so that the extra protruding portion is formed after coil winding. Had to do.

In order to solve the above problems, recently,
For example, as shown in FIGS. 14 to 16, a yoke portion iron core 5 in which a predetermined number of ring-shaped yoke pieces 5a are stacked, a tooth portion iron core support ring 6 formed concentrically with the yoke portion iron core 5, and the support. The tooth core 7 is formed by laminating a predetermined number of magnetic pole pieces 7a, the tips of which are detachably joined to the ring 6, and a coil (not shown) is further wound around the slot 10 of the tooth core 7 and then the tooth core is formed. The other end of 7 is press-fitted into the fitting hole 5b of the yoke core 5, and then the tooth core support ring 6 is removed from the tooth core 7 to form the stator core 8.

[0005]

In the conventional structure as described above, the yoke core and the tooth core are punched by pressing using a silicon steel strip (not shown), and
In the punching step of the silicon steel strip, a well-known half-punched protrusion 9 that is formed on the yoke piece and the magnetic pole piece at the same time is used, and the yoke piece and the magnetic pole piece are laminated and fixed so as not to come apart from each other. A yoke portion core and a tooth portion core are respectively formed, and the tooth portion core is radially arranged on a tooth portion core support ring concentrically provided with the yoke portion core as shown in FIG. Since the coils are wound around the slots between the tooth cores, that is, a plurality of tooth cores that are individually laminated are radially arranged using the support ring each time the coil is wound. Therefore, it takes a lot of time and effort to manufacture the stator core, which is a major factor that hinders the mass production of the stator core.

When manufacturing the stator core, a tooth core support ring is required every time each stator core is manufactured, so that the manufacturing cost of the stator core is increased and the stator core is manufactured. If the diameter of the iron core is different, a support ring corresponding to the different diameter must be prepared in advance, and there is a problem in that the management and storage of the support ring must be taken care of and labor is required. Furthermore, after manufacturing the stator core, magnetic flux generated by energizing the coil leaks through the tooth core support ring connecting the tooth cores to each other,
As a result of this being a factor of vibration and abnormal noise of the electric motor, the support ring must be removed after manufacturing the stator core, which also hinders mass production of the stator core and simplifies the manufacturing process. It was a problem that could not be facilitated.

The present invention solves the above-mentioned various problems. Even if there is a bridging portion connecting the tooth cores to each other, the characteristics of the electric motor can be maintained without being obstructed by the bridging portion. In addition, by facilitating a series of manufacturing processes such as stacking and fixing of the stator core and coil winding work, a stator core manufacturing method for obtaining an efficient and highly reliable electric motor is provided. To provide.

[0008]

In order to achieve the above-mentioned object, the present invention provides the yoke piece and the magnetic pole piece with a predetermined size in a state where the yoke piece and the magnetic pole piece are detachably joined to each other. A step of stacking a number of sheets and fixing them by caulking projections to form an iron core body composed of a yoke core and a magnetic pole core having a predetermined number of tooth cores; and a rotor insertion hole side of the core body. The gap between the tooth cores of is closed and bridged, and the entire circumference of the magnetic pole core including this bridge is molded with synthetic resin to form an insulation-treated portion having a resin insulation layer. A step of separating the magnetic pole core provided with the insulating portion from the yoke core, forming a coil by winding a coil conductor around a slot existing between each tooth core of the magnetic pole core; Connected to the yoke core of the magnetic pole core around which the coil is wound. The step of inserting an insulating member that covers the opening into the slot opening that is open to the end face side, and the magnetic pole core that is wound with the coil and that has the insulating member in the slot opening member is the yoke member core. Since the stator core is formed by the step of press-fitting and fitting into, the operation is as follows.

[0009]

As described above, in the present invention, in the step of punching out the yoke piece and the pole piece, the yoke piece is punched in the state where the pole piece is joined to the yoke piece, and the two members are joined together without being separated. Under these conditions, the protrusions for entanglement and crimping are engaged with each other and laminated and fixed to the yoke piece and the pole piece of the previous layer, so that the pole core is formed until the pole core is insulated with the synthetic resin. The tooth core can maintain the laminated state and can be reliably held by the yoke core.

Further, the tooth core is subjected to an insulation treatment to form a magnetic pole core in a state in which a gap between adjacent tooth cores is bridged in a closed manner before being separated from the yoke core. Therefore, since the tooth cores are connected to each other in a circular shape by the resin insulating layer of the insulation processing portion without being individually separated, the coil winding work of each slot can be smoothly and favorably performed. Moreover, since the insulating treated portion is made of synthetic resin, leakage of magnetic flux is eliminated by the presence of the bridging portion, and a high-performance electric motor can be assembled.

Further, since the magnetic pole core is formed of an insulating material by a synthetic resin, an insulating material is not required when the coil conductor is wound, and the tooth core located on the rotor insertion hole side after the stator core is assembled. Since it is not necessary to remove the insulation processing members bridging the gaps between them, it is possible to facilitate a series of manufacturing processes such as lamination and fixing of the stator core, insulation processing, coil winding work, etc. The productivity of the child iron core can be significantly improved.

[0012]

Embodiments of the present invention will be described below with reference to FIGS. In FIG. 1, 11 is a yoke portion iron core 12.
1 shows a stator core element body provided with a magnetic pole core 14 by press-fitting one end of a predetermined number of tooth cores 13. Next, the manufacturing process of the stator core element body 11 will be described with reference to steps A to E shown in FIGS.

Steps A to E shown in FIGS. 7 and 8 are
Silicon steel strip X in a single progressive die (not shown)
Is sequentially fed step by step, the required number of the cylindrical yoke pieces a forming the yoke core 12 and the magnetic pole core 14 from the silicon steel strip X (16 in this example).
This shows the step of punching out each of the magnetic pole pieces b for forming the individual tooth cores 13.

In punching the silicon steel strip X, in step A, a portion s corresponding to a space (slot) between the magnetic pole pieces b is first punched from the silicon steel strip X. Subsequently, in step B, protrusions d and e for entanglement and crimping are provided on the silicon steel strip X at positions corresponding to the yoke piece a and the magnetic pole piece b, respectively. As shown in the enlarged view of FIG. 9, these protrusions d and e are formed so that the protruding length is not more than the plate thickness of the silicon steel strip X and the silicon steel strip X on the opposite side from which the protrusions d and e project. For example, a concave portion f having a trapezoidal cross section is inevitably formed on the end face of the magnetic pole piece, and when the yoke piece a and the magnetic pole piece b are stacked, the protrusions d and e of the adjacent yoke and magnetic pole pieces are formed. And the concave portion f are entwined with each other.

Next, in step C, the yoke piece a
By punching out the silicon steel strip X with a diameter corresponding to the inner diameter of the (stator core), a space portion g (this space portion g serves as a rotor insertion hole (not shown)) is formed. . Next, in Step D, a step of punching out each of the magnetic pole pieces b for forming the required number of tooth cores 13 constituting the magnetic pole core 14 is shown. In this example, 16 pieces are formed as shown in FIG. However, the magnetic pole pieces b once punched can be re-joined to the silicon steel strip X at the punching place of the silicon steel strip X without being laminated as they are. It is like this.

In FIG. 10, the pole piece b is punched out,
A schematic structure of the pole piece rejoining device 15 for rejoining this at the punching place will be described. This device 15 is installed in the step D, and its structure is composed of a punch holder 16 and a die holder 17, as shown in FIG. 10. The punch holder 16 has a punch 18 having a die for punching a magnetic pole piece b at the center. A press ring 19 for pressing the cutting material in a non-swinging manner at the time of punching is integrally attached to the peripheral side of the punch 18 so that it can be lifted and lowered by a drive source (not shown). Further, the die holder 17 is constructed such that the facing plate 20 is opposed to the punch 18 and is housed in the die 21 so as to be vertically movable via a spring member 22. Then, in step D, when the pole piece b is punched from the silicon steel strip X by the punch 18, the pole piece b is once mounted on the facing plate 20 while being pressed by the punch 18. At this time, the facing plate 20 is attached to the spring member 2.
Since it is supported by 2, the punch 18 descends to the position indicated by the chain double-dashed line in FIG. 10, and at this point the silicon steel strip X is pressed and held by the pressing ring 19 on the die 21. , It does not rock.

When the punch 18 starts to rise (return to the original position) in the above-mentioned state, the opposing plate 20 in the die 21 is also urged by the spring member 22 to follow the operation of the punch 18 and the die 21. Move up inside. Therefore, the punched magnetic pole pieces b are sandwiched by the punch 18 and the counter plate 20, respectively, and move up to the position of the silicon steel strip X without rocking. In this case, in the silicon steel strip X punched out of the magnetic pole pieces b, the pressing state of the holding ring 19 of the movable body 16 is canceled by the rise of the punch 18, but the silicon steel strip X itself is stepwise. As a result of being held so as not to swing by a steel strip feeding device (not shown) for progressively feeding the inside of the die, the punched magnetic pole piece b is moved in the step D shown in FIG. Therefore, it is possible to easily rejoin the hole h of the silicon steel strip X.

In step D, the punched pole piece b is rejoined to the hole h of the silicon steel strip X, and then the silicon steel strip X is fed forward in the final step E with the pole piece b joined. In step E, the yoke piece a is attached to the silicon steel strip X.
Punch out from. In step E, only the yoke piece a is punched out, but the yoke piece a is punched out because the pole piece b is previously joined to the silicon steel strip X. The inner side of the punching blade portion, ie, the yoke piece a, punches the outer side of the hole h where the magnetic pole piece b is joined. As a result, the magnetic pole piece b is held in the punching die. Since the yoke piece a is punched, it is possible to reliably prevent the pole piece b from coming off the punching hole h when the yoke piece a is punched.

Then, the yoke piece a punched from the silicon steel strip X is, as shown in FIG. 11, in the housing frame 23 of the iron core element plate k attached to the step E in the state where the magnetic pole piece b is joined. It is mounted on a lift table 24 which is operated by a drive source such as a cylinder (not shown) housed so as to be movable up and down. The elevating table 24 is located at the uppermost end in the frame body 23 that accommodates the iron core plate k at the start of punching. Further, the frame body 23 accommodating the lifting table 24 is installed directly below a punching die (not shown) at step E with almost no space. That is, silicon steel strip X
When the yoke piece a is punched out from the bottom, and when the yoke piece a is mounted on the lift table 24, the magnetic pole piece b is installed with a space such that the impact does not cause the pole piece b to separate from the hole h. Further, the inner peripheral surface of the housing frame 23 is formed in a taper shape such that the diameter dimension of the upper opening end thereof is slightly larger than the diameter dimension of the lower opening end thereof, and the diameter dimension of the lower opening end thereof is the yoke. Slightly smaller than the outer diameter of piece a (within approximately 1 mm)
Opened with large dimensions.

Therefore, the yoke piece a formed by joining the magnetic pole pieces b punched out in step E, as shown in FIGS.
As they are successively placed on the lifting table 24 and stacked, the magnetic poles are adjacent to the yoke pieces a via the protrusions d and e for caulking and caulking formed on the yoke pieces a and the magnetic pole pieces b, and the concave portions f. The piece b and the piece b are temporarily fixed in order while being joined to each other. That is, the yoke piece a punched by joining the magnetic pole pieces b
When the next yoke piece a is sequentially stacked on the yoke piece a already punched and stacked on the lifting table 24,
The protrusions d and e provided on the yoke piece a and the magnetic pole piece b for entanglement and caulking are fitted into the concave portions f of the previous (adjacent to the lower side) yoke piece a and the magnetic pole piece b to temporarily fix them. In this state, the yoke pieces a and the magnetic pole pieces b which are adjacent to each other (in the stacking direction) are sequentially laminated integrally to form an iron core element plate k. And
As the number of stacked sheets increases, the elevating table 24 sequentially descends as shown in FIG. 12 while maintaining the optimum distance between the uppermost yoke piece a and the pre-punching silicon steel strip X.
At the time of this lowering, the inner peripheral surface of the housing frame 23 has a smaller diameter (tapered shape) on the lower opening end side than the upper opening end side, but the diameter is small (tapered).
Since the protrusions d and e for entanglement and crimping and the recessed portion f can be satisfactorily fitted to each other without displacement, it is possible to reliably prevent the adjacent yoke pieces a and the magnetic pole pieces b from coming apart. it can.

Then, in step E, the yoke pieces a are punched out a predetermined number of times to stack the core body 25 for one electric motor, and as shown in FIG.
Moves down to the same height as the conveyor 26 installed at the lower part of the housing frame 23, and pulls out the core element body 25 from the housing frame 23. Thereafter, the iron core element 25 is sent out onto the conveyer conveyor 26 by a pusher 27 driven by a cylinder or the like, and a press device (not shown) for normally fitting the entanglement and caulking projections d and e into the concave portion f. ), And by tightly fitting the entanglement and caulking projections d and e into the recess f as shown in FIG.
As shown in FIG. 2, a stator core element body 11 including a yoke core 12 and a magnetic pole core 14 formed by joining one end of a predetermined number of tooth cores 13 to the yoke core 12 is formed. It is a thing.

Next, of the yoke core 12 and the magnetic pole core 14 forming the iron core body 25 provided in the punching process of the silicon steel strip X, only the magnetic pole core 14 is shown in FIG. In this state, insulating treatment is performed using synthetic resin. This insulation treatment is performed, for example, by applying a release agent to the yoke core 12 to prevent the synthetic resin from adhering, or by covering only the yoke core 12 so that the synthetic resin does not adhere to the inside of the mold, The iron core 14 is molded with a synthetic resin. The magnetic pole iron core 14 is subjected to an insulation treatment. When the magnetic pole iron core 14 is separated from the yoke iron core 12, the tooth cores 13 are distorted or concentric with respect to the yoke iron core 12. To prevent the re-joining of the coil conductor and the inability to wind the coil conductor around the slot 28 between the tooth cores 13.

As described above, the iron core element 25 is put into a mold (not shown), and only the magnetic pole iron core 14 is molded using a synthetic resin. For example, as shown in FIG. A resin insulating layer 29 is formed only on the iron core 14 over the entire area. After the core body 25 having the resin insulating layer 29 is molded, the magnetic pole core 14 is extracted from the yoke core 12 as shown in FIG. In this case, since no resin is attached to the yoke core 12, the magnetic pole core 1
4 can be easily removed. That is, the tooth core 13
Is removed from the hole h to release the joint with the yoke core 12. Yoke part iron core 12 to tooth part iron core 13
When the tooth core 13 is pulled out, as shown in FIG. 4, the end portion j on the rotor R side shown in FIG. The narrow gap P (see FIG. 1) is closed by the resin insulation layer 29, and the tooth cores 13 are connected and held continuously by bridging connection, so that the yoke core 12 is connected to the magnetic pole cores. Even if 14 is pulled out, each tooth core 13 which constitutes this
In the above, the resin insulating layer 29 can be pulled out while maintaining its arrangement state accurately without being disjointed.

After the magnetic pole core 14 is removed from the yoke core 12, the magnetic pole core 14 is set in a winding machine (not shown), and coil conductors are inserted in the slots 28 between the tooth cores 13 as shown in FIG. And coil 3 around the magnetic pole core 14
0 is wound. In this case, since the magnetic pole core 14 is opened on the side of the joint portion i with the yoke portion core 12 and the entire area except the joint portion i is covered with the resin insulating layer 29, an insulating material such as slot insulation is used. The coil 30 can be wound well without using it. When the winding of the coil 30 is completed as described above, as shown in FIG. 6, the opening of the magnetic pole core 14 on the side of the joint portion i is closed by the insulating member m, and then the magnetic pole core 14 is formed into a ring-shaped yoke portion. In the iron core 12,
By press-fitting and fitting using the hole h, the assembly of the stator core 31 including the yoke core 12 and the magnetic pole core 14 around which the coil 30 is wound is completed.

[0025]

As described above, according to the method for manufacturing the motor stator core of the present invention, the magnetic pole core is joined to the yoke core in the state where the yoke core and the magnetic pole core are joined. Since the whole area except the part is molded with a synthetic resin and subjected to insulation treatment, even if the magnetic pole core is disconnected from the yoke core core after this insulation treatment, Resin insulation that bridges the narrow gap between adjacent cores with one end of each tooth core (that is, the end located in the space on the rotor insertion hole side that is not joined to the yoke core) Since the magnetic pole cores are continuously connected in layers, the tooth cores do not fall apart even if the magnetic pole cores are separated from the yoke cores, so the coil winding work of the magnetic pole cores can be performed smoothly and satisfactorily. A member that connects the gap between the tooth cores Since that is formed of synthetic resin, it is also without any magnetic flux leakage between teeth cores, it is possible to provide a high performance motor. Moreover, since it is not necessary to remove the resin insulating layer bridging the gaps between the tooth cores after the stator core is assembled, it is possible to easily improve the efficiency and automation of the manufacturing process of the stator core. it can.

Further, according to the present invention, when the yoke pieces constituting the yoke core are punched, the yoke pieces are rejoined to the punched holes of the tooth core by means of rejoining the yoke pieces. Since it is designed to perform punching, it is possible to eliminate the trouble of separately storing the pole piece that was punched first and then reconnecting the pole piece to the yoke piece after punching the yoke piece. , The yoke piece and the magnetic pole piece in the split type stator core can be easily handled.

In addition, after the yoke pieces have been punched out, the yoke pieces and the pole pieces are joined together,
The pole pieces are entwined and crimped so that they are stacked and fixed while sequentially fixing them.This makes it possible to automate the stacking and fixing work of punched steel plates consisting of yoke piece pushing pole pieces. The manufacturing process of the stator core is partially simplified, automation is promoted, and the productivity of the highly reliable stator core can be improved.

[Brief description of drawings]

FIG. 1 is a plan view of a stator core manufactured by a manufacturing method of the present invention.

FIG. 2 is a plan view showing a stator core element body formed during the manufacturing of the stator core in the manufacturing method of the present invention.

FIG. 3 is an exploded perspective view of a yoke core and a magnetic pole core.

FIG. 4 is a plan view showing a state in which a magnetic pole core is subjected to an insulation treatment.

FIG. 5 is a plan view showing a state in which a coil is wound around a magnetic pole core that has been subjected to an insulation treatment.

FIG. 6 is an enlarged plan view showing a main part of a stator core.

FIG. 7 is a plan view showing a punched state in each step (A) to (C) of a silicon steel strip.

FIG. 8 is a plan view showing a punching state in each of steps (D) and (E).

FIG. 9 is an enlarged cross-sectional view showing a protrusion for entanglement and crimping.

FIG. 10 is a vertical sectional view schematically showing an apparatus for rejoining the pole pieces.

FIG. 11 is an explanatory diagram of a device for temporarily fixing a yoke piece and a magnetic pole piece.

FIG. 12 is a diagram for explaining the temporary fixing process in the same manner.

FIG. 13 is an explanatory diagram of a case where a temporarily fixed core body is conveyed.

FIG. 14 is a plan view showing a punched state of a conventional stator core.

FIG. 15 is a plan view of the pole piece of the same.

FIG. 16 is likewise a plan view of a yoke piece.

FIG. 17 is a perspective view of a stator core used in a conventional electric motor.

[Explanation of symbols]

 11 stator core element 12 yoke core 13 tooth core 14 magnetic pole core 15 rejoining device 18 punch 20 facing plate 25 core core body 29 resin insulation layer 30 coil 31 stator core a yoke piece b pole piece d for entanglement Protrusions e Entangling and crimping protrusions f Recessed portions h Holes i Joint portions j End portions k Core plate

Claims (3)

[Claims] 1. A step of forming a protrusion for caulking on a ring-shaped yoke piece and a pole piece concentrically arranged with the yoke piece; and after punching the pole piece, the pole piece is temporarily cut. A step of re-coupling with the punched portion, a step of punching the yoke piece with the pole piece rejoined, and a state of joining the yoke piece and the pole piece with each other, for entanglement and crimping with the yoke piece and the pole piece of the previous layer Stacking while temporarily fixing through the projections, and stacking a required number of the temporarily fixed yoke piece magnetic pole pieces, and then fixing the entanglement and crimping projections normally, and an iron core including a yoke core and a magnetic pole core A step of forming a body,
Insulating the magnetic pole core of this core body with a synthetic resin to connect the required number of tooth cores constituting the magnetic pole core to each other, and separating the magnetic pole core subjected to the insulating process from the yoke core. A stator core of an electric motor, characterized by comprising a step and a step of winding the coil around the magnetic pole core and press-fitting the magnetic pole core into the yoke core. Production method. 2. The step of re-joining the magnetic pole iron core is provided with an opposing plate on the die side that moves up and down following the up-and-down movement of the punch, and the magnetic pole piece punched by the punch is punched with the opposing plate. A stator core for an electric motor according to claim 1, wherein the magnetic pole piece is clamped and lifted up and is rejoined to the hole of the silicon steel strip when the clamp is released. Method. 3. The step of temporarily fixing the yoke piece and the pole piece to the member of the previous layer in a state where the yoke piece and the pole piece are joined, after punching the yoke piece, the lower part is joined to the yoke piece and the pole piece. The sequentially accommodating members are temporarily fixed to each other through a tangling and caulking projection as they are sequentially stacked and accommodated in a cylindrical accommodating frame body that is slightly inclined in the central direction. 1. A method for manufacturing a stator core of a motor according to 1.