JPH08214484A - Manufacture of stator for flat type motor - Google Patents

Abstract

PURPOSE: To prevent the breakage of magnetic wedges fitted in slots when the wedges are machined by forming the wedges in projecting shapes with projecting parts having heights higher than the depths of the openings of the slots and, after protruding the head sections of the wedges from the gap-side surface of an iron core and integrally molding the iron core and coils with a resin, machining the iron core to a specific size from the gap-side surface of the iron core. CONSTITUTION: An iron core 2 is formed by winding a band-shaped steel plate having slots 3. After a slot insulator 7 and coil 4 are housed in each slot 3, the upper section of the coil 4 is fixed with an insulating wedge 8. Then a magnetic wedge 9 which has a projecting shape and the projecting section of which has a height which is higher than the depth of the opening 6 of the slot 3 is inserted into the opening 6 of each slot. After the wedges 9 are inserted into the openings 6 of the slots 3, the iron core 2 and coils 4 are integrally molded with a resin and, at the same time, an insulating resin layer 5 is provided on the gap-side surface of the core 2. Then the core 2 is finished to a specific size by machining the core 2 from the gap-side surface side. Since the projecting sections 9A of the wedges 9 are united with the core 2 by means of the resin layer 5, the sections 9A are not broken when the core 2 is machined.

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 of a flat type electric motor.

[0002]

2. Description of the Related Art The stator structure of a conventional flat type electric motor is shown in FIG.
As shown in (This drawing is used because there is no structural difference between the prior art and the present invention in the state in which the magnetic wedge is not clearly shown), it has a slot 3 formed by punching along one side of a strip shape (not shown). The strip-shaped iron plate is wound to form the iron core 2. The iron core 2 is fixed on the flange 1, the slot insulator 7 and the coil 4 are housed in the slots 3, and the upper part of the coil 4 is fixed by an insulating wedge 8.

A magnetic wedge 9 having a convex projection 9A as shown in FIG. 4 is inserted into the slot opening 6 near the head of the slot 3 (see FIG. 5). In this state, the core 2 and the coil 4 are molded by resin to be integrated with each other, and a layer of the insulating resin 5 is provided on the void surface of the core 2 (see FIG. 6). Next, turning is performed from the void side of the iron core 2 to form a stator having specified dimensions (see FIG. 2).

In order to improve the magnetic flux distribution in the air gap of the flat type motor thus formed, as shown in FIG. 4, a magnetic wedge 9 having a convex cross section is provided in the slot opening 6 at the upper part of the insulating wedge 8 mounted. Put on. And the coil 4 and the iron core 2
Is integrally molded with an insulating resin to form an insulating resin layer 10 up to the void-side upper surface of the iron core 2 (see FIG. 6). After that, the insulating resin layer 10 and the iron core 2 are processed into a predetermined size by turning from the void side of the iron core 2 to form a machined surface 11 on the void surface. Then, the stator of the flat type electric motor integrally molded with the insulating resin as shown in FIG. 2 is obtained.

[0005]

When formed in this way, since the projection 9A of the magnetic wedge 9 does not protrude from the void surface of the iron core 2 and is integrally molded with the insulating resin, the slot opening 6 is formed. A gap 12 is formed between the projecting portion 9A of the magnetic wedge 9 and the void surface of the iron core 2. Since the gap 12 is filled with resin at the time of molding, even if the processed surface 11 is formed, the gap 1
2 has no magnetic wedge 9. Therefore, bridging by the magnetic wedge 9 cannot be formed in the slot opening 6, and the effect of reducing the pulsation of magnetic flux by the magnetic wedge 9 on the void surface of the iron core 2 and improving the efficiency and noise cannot be sufficiently exerted.

Further, since the resin 12 remaining in the gap 12 of the slot opening 6 has a narrow and thin gap 12, the sharpness of the bite will be deteriorated unless the bite chips are replaced for each iron core 2 during turning. As a result, the resin may be partially damaged or peeled off. If it is used in this state, damage or peeling may proceed further, and the damaged material may scatter on the void surface of the iron core 2 to cause damage to the rotor or failure of the electric motor.

An object of the present invention is to improve the above-mentioned problems, and an object thereof is to provide a method for manufacturing a stator of a flat type electric motor, which allows a mounted magnetic wedge to exhibit predetermined performance without being damaged during machining.

[0008]

According to the present invention, a coil is housed in a slot of an iron core, a magnetic wedge is mounted, and then integrally molded by resin molding. The magnetic wedge is formed in a convex shape so that the height of the protrusion is higher than the depth of the slot opening.The head of this magnetic wedge is projected from the surface of the iron core cavity side and molded integrally with a resin mold, and then specified from the cavity side. This is a stator manufacturing method in which an insulating resin, an iron core void surface, and a magnetic wedge are formed on the same plane by dimension processing.

According to this manufacturing method, the stator integrated by the resin mold is machined from the core void side while the protrusion of the resin and the magnetic wedge is integrally machined, and the core void surface is also machined. The protrusion of the wedge is not damaged by machining and is positioned in a predetermined space in the gap of the slot opening to exhibit the function of the magnetic wedge.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view before turning, in which a protrusion of a magnetic wedge mounted in a slot protrudes from the core void surface and is resin-molded to provide an insulating resin layer on the core void surface. FIG. 2 is a sectional view of a stator of a flat type electric motor equipped with a magnetic wedge.

First, a method of forming the stator will be described. An iron core 2 is formed by winding a strip-shaped iron plate having slots 3 punched along one side of a strip (not shown). The iron core 2 is fixed on the flange 1, the slot insulator 7 and the coil 4 are housed in the slots 3, and the upper part of the coil 4 is fixed by an insulating wedge 8. Slot opening 6 near slot 3 head
A magnetic wedge 9 having a convex shape and a height of the protrusion 9A higher than the depth 1 of the slot opening 6 is inserted in the. At this time, since the height of the projection 9A is high, the head of the projection 9A projects from the void surface of the iron core 2. In this state, the core 2 and the coil 4 are molded by resin to be integrated with each other, and a layer of the insulating resin 5 is provided on the void surface of the core 2 (see FIG. 1). Next, turning is performed from the void side of the iron core 2 to form a stator having specified dimensions (see FIG. 2).

Next, the operation will be described. Projection 9A of magnetic wedge 9
Is also integrated with the iron core 2 by a layer of the insulating resin 5 formed on the void surface of the iron core 2, so that even when turning from the void surface side of the iron core 2, the insulating resin 5 layer and the iron core 2 are integrally processed. Therefore, the protrusion 9A is processed without being damaged. As a result, the magnetic wedge 9 is attached to the slot opening 6 in a predetermined manner to form a bridge, and the pulsation of the magnetic flux due to the magnetic wedge 9 on the void surface of the iron core 2 is reduced to improve efficiency and noise. It can be sufficiently exhibited, and iron loss can be reduced when used in a high frequency power source as shown in FIG.

Further, the problem of replacing the insert of each bite for each iron core 2 during turning, which has occurred conventionally, also causes the breakage or peeling of the resin or the magnetic wedge even if the sharpness of the bite is reduced. Has disappeared and productivity has improved. Further, the reliability of the electric motor is improved because there is no risk of damage to the rotor or damage to the electric motor due to broken objects.

[0014]

As described above, according to the present invention, a magnetic wedge is attached to the slot opening in a predetermined manner to form a bridge, and the pulsation of magnetic flux due to the magnetic wedge on the void surface of the iron core is reduced to improve efficiency and noise. The original effect of the magnetic wedge that it can fully exert its effect can be obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view before turning, in which a protrusion of a magnetic wedge protrudes from an iron core void surface and is resin-molded to provide an insulating resin layer on the iron core void surface,

FIG. 2 is a sectional view of a stator of a flat type electric motor equipped with a magnetic wedge,

FIG. 3 is a characteristic comparison diagram,

FIG. 4 is a perspective view of a magnetic wedge,

FIG. 5 is a cross-sectional view of a semi-closed slot showing mounting of a conventional magnetic wedge,

FIG. 6 is a view corresponding to FIG. 1 of the related art.

[Explanation of symbols]

2 ... iron core, 3 ... slot, 5 ... insulating resin,
6 ... Slot opening, 9 ... Magnetic wedge, 9A ...
Magnetic wedge protrusion, 10 ... Insulating resin layer, 11 ... Processed surface.

Claims (1)

[Claims] 1. A method for manufacturing a stator of a flat type electric motor, comprising a coil housed in a slot of an iron core, a magnetic wedge mounted on the core, and then integrally molded by resin molding. Is formed to have a height higher than the depth of the slot opening, and the head of the protrusion of this magnetic wedge is made to protrude from the surface of the iron core cavity side and molded integrally with resin, and the specified dimension is machined from the cavity side for insulation. A stator manufacturing method for a flat type electric motor, characterized in that a resin, an iron core void surface and a magnetic wedge are formed on the same plane.