JPS6012857B2 - Electric motor stator mechanism - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a stator mechanism for a rotating electrical machine, particularly an electric motor.

It is known that in order to obtain a rotating electric machine with high operating efficiency and reliability, and with low manufacturing costs, various and sometimes contradictory conditions must be met.

For example, stationary or fixed structures such as stator frames, stator cases, and stator housings are used to protect the windings attached to the stator from shocks that may be experienced during manufacturing, transportation, or normal operation. Must have structural integrity. In order to avoid terminological confusion, the term "fixed composite structure" will be used hereinafter to refer to the winding support member (e.g., stator core), the winding supported by the winding support member, and The term ``terminal'' is used to include a housing for physically surrounding and protecting the winding and/or the winding support member.

The fixed composite structure surrounding the rotor (which is also a type of "composite structure") preferably has a sound-insulating effect, that is, the property of suppressing the noise generated during operation of the rotating electrical machine.

This composite structure is capable of supporting a bearing mechanism precisely and reliably, such that a particular surface of the structure is movably supported with respect to the structure, such as a particular surface of a rotor. It must be possible to secure a predetermined gap between them. Rotating electrical machines are subject to repeated stresses resulting from thermal cycling or pulsating torque, as is unavoidable in AC induction motors, for example.

Therefore, fixed composite structures need to be able to withstand these stresses. Additionally, it is desirable to provide means for actively protecting the windings and terminal devices from mechanical shock, high temperatures, corrosive atmospheres, and various other environmental conditions encountered during operation. In addition to the above-mentioned favorable conditions, a stationary composite structure is very suitable if, at least in its housing part, it is capable of quickly and efficiently dissipating the heat generated by the windings, bearing arrangement and rotor. It's convenient.

The general conclusion reached after many years of research and development activity is that there are only a few methods that can satisfactorily solve the various problems associated with rotating electrical machines as described above.

A commonly used method is to use formed or cast metal parts that are sized to fit precisely into the stator core; The disadvantage of rotary electric machines is that they are surprisingly easily damaged due to handling errors.The rotary electric machines that are the subject of the present invention are made by stacking laminated plates together, and have a central entrance and a winding storage slot. A fixed composite structure includes a stator mechanism including a winding support member having a winding support member and a plurality of windings housed in slots of the winding support member, and a housing that houses the stator mechanism. .

The housing portion of the fixed composite structure contains numerous particulate materials,
For example, it is a mass of granular material made by bonding sand together using a heat-sensitive adhesive so as to surround the stator mechanism. The particulate material is compacted around the windings, winding support members, and cemented together to form a strong solid body. The countless gaps inside the solid body are occupied by adhesive. With a composite structure made in this way, it is no longer necessary to provide strict dimensional tolerances between the housing and the stator mechanism, as is necessary in conventional rotating machines. Additionally, its structural integrity and corrosion resistance are far superior to stator housings made using conventional formed steel or cast iron. Moreover, these excellent features do not sacrifice noise cancellation or heat dissipation, and in some cases, provide better noise cancellation than traditional steel or cast iron stator housings. There are things to do. In the present invention, inert particulate materials are compacted so as to substantially contact each other to form a porous solid body, and the voids are filled with a resin material to form a substantially rigid solid material, which constitutes a housing. However, the resin material is used in an amount sufficient to substantially fill the voids in the solid body, all or a significant portion of the particulate material is made finer than 100 mesh, and glass fiber is included in the inert material. This makes it possible to ensure sufficient mechanical strength, self-shape retention, and heat dissipation even if the inert granular material used is quite fine. Examples of the invention will be described in detail.

Note that although a motor will be explained below as an example, the present invention is applicable to all kinds of rotating electric machines, and
It is not limited to the evening. First, FIGS. 1 and 2 show a rotating electric machine having a stator mechanism according to an embodiment of the present invention, in particular, a motor 20 having a bearing integrated with the rotating mechanism.

This motor 20 has a fixed composite structure 22 and a bearing mechanism 23, and on the side of the bearing is a bearing support member 24 attached to the fixed composite structure 22, a sleeve bearing 26 fitted and fixed in this support part village, and The lubricating device consists of an oil feed core 27 and an oil cover 28. motor 20
further includes a rotation mechanism consisting of a rotor 29 and a shaft 30. The rotor 29 is made of magnetic laminations and is equipped with a conventional squirrel cage secondary winding. Coffin bolts 31, 32, and 33 are fixed to the bearing support member 24 by spot welding or the like, and these bolts are used to attach the motor to a predetermined support member. An oil reservoir formed in the cover 28 of the lubricating device contains a well-known oil-impregnated material such as wool felt, from which the oil supply wick 2 is inserted.
7, lubricating oil such as motor oil is supplied to the shaft 30 and the bearing mechanism 23. The cover 28 is secured to the bearing support member 24 by the locking action of a fastener 36 provided on the cover and an opening 34 formed in the bearing support member 24.

The fixed composite structure 22 includes a stator winding and a laminated stator iron D3.
It includes a stator mechanism consisting of 7. Stator core 37
It has a rounded magnetic pole type, and has an annular yoke portion and teeth or salient magnetic pole portions 38 formed at intervals on the inside of this yoke portion, and between these salient magnetic pole portions. A winding slot is made in the winding to accommodate the winding. Further, the tip of the salient pole portion 38 has an arcuate surface, which forms a gateway 39 for housing the rotor. The winding slot extends through all the laminated plates of the iron core 37 in all axial directions,
The coil side portion of the winding 41 is accommodated.

In the illustrated example, the winding 41 consists of coils forming four magnetic poles, and these coils are made by winding a predetermined number of insulated wires around each magnetic pole. Both ends of this four-pole winding 41 are connected to terminal members 42. Elongated bottles made of molded plastic or other materials4
0 penetrates the iron core 37 and extends beyond each protruding magnetic pole part or salient pole part 38 in the axial direction, and allows the winding coil accommodated in the winding slot to escape from the slot to the rotor center entrance 39. I'm keeping it on hold so it doesn't happen again. The terminal device 42 is immovably embedded within the fixed composite structure 22.

That is, the terminal device 42 consists of conductive terminals 43 and 44 and an insulating terminal support plate 46 that is flat enough to be made of an electrically insulating material such as fiberboard, thermosetting plastic, mica, etc., and a portion of the terminals 43 and 44 is It is fixed to the support plate 46 with rivets or the like, and the other parts protrude to the outside of the composite structure 22. Terminals 43, 44 thus constitute a quick-connect type terminal arrangement that can be easily and quickly connected to a power source. Since the terminal device 42 is substantially completely embedded and fixed within the fixed composite structure 22, it is extremely difficult, if not impossible, to remove the terminals 43, 44 from this composite structure. Conversely, it is virtually impossible for the electrical connection between the winding 41 and the terminal device to break, which is even more important. It is known that approximately 50% of magnetic field disturbances, or magnetic field-related failures, in conventional motors are due to terminal device failures, particularly loose terminals or broken connections between the terminals and the windings. It is being Therefore, the configuration of the motor terminal device described above has significant advantages over conventional terminal devices. During operation of the motor, noise is generated due to mechanical movement of the rotor within the center opening of the stator core.

Further, in a motor having a conventional structure, when an excitation current flows through the windings, the windings and laminated plates tend to vibrate or make a humming noise. Furthermore, the stationary parts of the motor and the bearing mechanism generate heat during operation. The motor according to the illustrated embodiment solves these problems and has an excellent heat dissipation effect and noise elimination effect during operation. The fixed composite structure 22 includes a winding support member, that is, a stator 30 and a winding 41.
and a porous housing consisting of an aggregate or mass of inert particulate material packed together around the terminal device 42.

Note that the term "porosity" as used herein means that there are gaps, cracks, etc. inside the material. An adhesive is injected into the numerous interstices of the inert particulate material, which binds the inert particulate materials together into one strong aggregate or solid body. The aggregate or now solid body then forms a housing, which is the main component of the fixed composite structure 22. Note that the adhesive injected into the porous solid body also serves to bond the solid body, the winding support material (stator core), the winding wire, and the terminal mounting together. A variety of inert particulate materials can be utilized to create the aggregated solids described above.

However, the necessary conditions are that the winding support member, the winding terminal device, and the insulation used in the winding and winding support member be able to withstand the temperatures that occur during the manufacturing process, and that they must be able to withstand the temperatures that occur during the manufacturing process. It must not be a magnetic material or a dew conductor. These requirements also apply when selecting the adhesive used to consolidate the inert particulate material. Granular refractory materials are particularly suitable as inexpensive inert particulate materials that are generally readily available. Examples include various ores, rocks, sand, etc. FIG. 3 shows the structural organization of the housing of the composite structure 22 shown in FIG. 1, which is created by arbitrarily collecting ordinary sand, and this is reproduced from a microscopic photograph of the surface of the housing. This is what I did.

The heat-sensitive adhesive injected into the numerous interstices within the aggregated solids of sand was virtually transparent. As can be seen from Figure 3,
Adjacent sand particles ``for example, particles 47, 48, 49,
The gap between 50 is occupied by an adhesive which adhesively bonds the granular sand together, as well as the stator core 37 and the windings 41 (see FIG. 2). The presence of the smallest particles 51 was observed, but these appear to be fine grains of sand or impurities that were present in the sand. Figure 3 is an isometric reproduction of a microscopic photograph of the surface of the aforementioned porous housing, that is, an aggregated solid body of inert granular material, which was enlarged using a microscope with a magnification of 7 pitches. , for example, granular sand 47,48
,49? The physical interrelationship of the 50 mags is obvious at a glance.

Although it cannot be clearly seen in the diagram because it is transparent, these countless pieces of sand are firmly bound together by an adhesive that fills the gaps between the pieces of sand. Generally, sand or other particulate material having a wide variety of sizes can be used, but preferably about 5% by weight of the amount used is particulate material having a particle size of 40 to 100 mesh. It is preferable to use the substance feces.

In addition, the American Founders Association (AmericanFo
It is desirable that the fineness be within the 45 to 5 neck range of the men's society standard. When a granular material having this level of fineness is used, the surface texture of the resulting aggregated solid body is almost indistinguishable from that of cast iron. The granular material used to make the motor of the example shown in Figure 1 was river sand containing 90 to 90% by mass of silica (Si02), about 2% by weight of clay, and trace amounts of various other components. It contained virtually no metal salts or steel. When using such natural sand, it is best to dry it thoroughly beforehand, roughen it extremely, and remove the sand to prevent the formation of irregular surface textures. Therefore, the well-known Femiswhee
l) Use a forced dryer to dry the sand at approximately 205°C (4000F)
It was heated and dried at a temperature of . After this treatment, the sand contained 0.0% by weight of water and 0.3% by weight of dust. Thereafter, the sand was sieved through a screen with a mesh size of 300, and only the sand that passed this was used. The results of the sieving tests for the sand samples used are listed in Table 1 for reference. A standardized method was used to conduct this test. Note that since sand larger than 30 mesh was already removed prior to the test, all the sand in the sample tested passed through the 30 mesh screen. Table 1 lists the test results for the two samples, as well as the average value of the test results for these two samples. Although sand is used in the illustrated embodiment of the invention, other inert particulate materials may be used.

However, in that case, there may be differences in economic efficiency. It is possible to use slate, chalk, zirconia, alumina, calcium carbonate, mica, beryum oxide, magnesium oxide, or combinations thereof, as well as combinations of naturally occurring minerals such as ores.

For example, ``We actually tried using chromite instead of sand, but the resulting housing was black and its surface texture was very similar to that of cast iron.Furthermore, its structural characteristics were similar to those of the sand. In order to make the motor of the illustrated embodiment, sand containing various sizes in the range mentioned above was used from an economical point of view. However, satisfactory results can also be obtained using particulate materials having virtually the same size.Aside from economic factors, the main factors to consider when misting particulate materials are: For example, if only particulate materials larger than ~30 mesh are used, it is the structural integrity and appearance of the constructed structure that binds these particulate materials together and the interparticles at the surface of the resulting aggregated solid. Unless a large amount of adhesive is used to completely fill the gaps, the surface of the aggregated solid body will be relatively rough.However, using a large amount of adhesive may cause problems. Not only is the economy
The surface of the aggregated solid body is the “resin excess surface” which will be explained in detail later.
becomes. On the other hand, ``Based on the sample testing described above, it appears that if all particulate material sizes were significantly smaller than 100 mesh, the structural integrity or strength of the resulting aggregated solid body would be significantly reduced.

Clear evidence of this is the appearance of cracks and surface cracks in the aggregated solids after the adhesive has cured. However, when the size of the particulate material was substantially 100 mesh, sufficient structural integrity was obtained. Therefore, if all or a significant portion of the granular material used is finer than 100 mesh, it is necessary to take measures to prevent cracks and crevices from forming in the resulting aggregated solid body. To this end, according to the invention, glass fibers, such as those disclosed in US Pat. No. 2,820,914, are included as reinforcing material in the inert material. In the present invention, various adhesives can be used to bond the particulate materials together and also to the windings and winding supports.

However, regardless of its composition, the adhesive preferably has the following properties. The inert particulate material can be economically combined into one solid body, the inert particulate material can be bonded together to other components of the composite, such as windings, cores, be compatible with insulators, etc., and have no detrimental effect on them (in other words, be inert with respect to other components in the composite), and during manufacturing, testing, and operation processes. These include being able to withstand the temperatures that occur. Additionally, it is desired that the adhesive be tacky enough to penetrate completely into the interstices between the particulate materials and, after curing, to form a substantially amorphous aggregated solid. It has been found that a two-component heat-sensitive adhesive of thermosetting synthetic resin type has the above-mentioned properties. When using two-component thermoset resin adhesives, the base material may be phthalic or non-phthalic type polyesters, epoxies (e.g.
Bisphenol A, novolak, cycloaliphatic), certain phenolic resins, polybutadiene resins, eboxy acrylic resins, eboxy polyester resins, etc. can be used.

Furthermore, a component to increase the flexural strength when the adhesive layer is cured, a catalyst to shorten the time required for the adhesive to harden or harden, and the resulting solid body are molded into the above-mentioned base material. It is effective to add a release agent to facilitate release from the mold.

The adhesive used to make the example motor was as follows.

55% by weight of polyester resin as a base material is mixed with 45% by weight of styrene as a component for increasing the flexural strength, and 1% by weight of styrene as a catalyst is mixed with 9% by weight of this mixture.
% by weight of tertiary brutipenzoate peroxide was added. Furthermore, 0.55% by weight of a mold release agent was added to 99.45% by weight of the above mixture. As a mold release agent, one commercially available under the name "Zelee" is available from DuPont's Organic Chemicals Division. Regardless of whether a Teflon-treated or non-Teflon-treated mold is used, a predetermined aggregated solid body can be produced without using a molding agent. The polyester resin used in the examples of the present invention is a non-phthalic polyester consisting of monobasic and polybasic acids and polyhydric alcohols, and is manufactured by Conchemco of Baltimore, Maryland, USA. Polyester molding agent M. It was commercially available under the name 519-C-111.

Another resinous base material is commercially available from the Dow Chemical Company of Michigan under the name "Derakane." This is disclosed in detail in US Pat. No. 3,367,992. The main component of the fixed composite structure 22, the housing, was made using approximately 71.2% sand and 28.8% adhesive by weight.

After injecting the adhesive into the gaps and holes inside the sand mass, it was heated at a temperature of 190 qo for 25 minutes to harden the adhesive. In order to shorten or extend the curing time as necessary, the heating temperature and the amount of catalyst used may be changed as appropriate. The weight percentages of the particulate material and the adhesive actually used can be varied as required, and in the case of the illustrated example, several solid composites were prepared experimentally with varying ratios between the two. were formed and appropriate ratios were determined based on a comparison of their physical properties.

The adhesive, particulate material, stator core, and windings are compatible with each other, and the desired quantitative interrelationship of the particulate material and adhesive used can be determined by physical inspection and structural testing of the resulting solid body. Generally speaking, the higher the amount of particulate matter and the lower the amount of adhesive, the better the heat dissipation and structural integrity of the resulting solid body (i.e., the absence of surface cracks, uniform surface texture, and relatively smooth surface texture). and have strong resistance to impact, crushing, and destruction). Using the minimum amount of adhesive necessary ensures that there is no more adhesive in the solid body than is necessary to fill the gaps between adjacent particulate materials in the solid body. If the amount of this adhesive is large, the resulting solid body will become porous as a whole, and the particulate matter on the surface will easily peel off.
In extreme cases, the solid object will crumble into pieces when dropped. On the other hand, given that the clearance or play between the motor center opening and the rotor is sometimes only 0.2794 ribs, it is difficult for the structure used in the motor to shed even a single particle from its surface. We must make sure that this does not happen.

If particulate matter, especially particles of abrasive refractory materials, get into the above-mentioned gaps during rotation of the motor, a major failure may occur, although the motor will not be destroyed. For example, noise may be generated, or the motor shaft may be restrained by the bearing, causing the rotor to stop moving. Also, if too much adhesive is used, the outer surface of the resulting solid structure becomes ``resin-rich'' and becomes as smooth as glass. This state poses a problem when attempting to bond other component devices. The volume of the porous solid obtained by aggregating the particulate matter as described above is determined mainly by the apparent volume occupied by the particulate matter.

Therefore, the density or proportion of the porous solid body impregnated with the adhesive is greater than the unit volume weight of the particulate material. For example, the unit volume weight of the dry sand used in making the motor of the illustrated embodiment was approximately 1.6 kg, and the adhesive of the fixed composite structure 22 made by collecting this sand was cured. The remaining density per unit volume was approximately 1.9 m. In addition, the pore volume, that is, the porosity of the sand in its loose state before it aggregated was about 34%. Since all the gaps and pores inside the solid body made by concentrating the sand should be occupied by the adhesive, the solid body after the adhesive has hardened will have a volume of approximately It will consist of 34% adhesive and approximately 66% sand.
The advantages of a motor with a stator mechanism according to the invention become apparent when comparing the characteristics of this motor with those of conventional motors having housings made of cast iron and drawn steel parts. Take, for example, the structural integrity of a motor, its ability to withstand physical abuse without damage to its mechanical and electrical components. Examples of such abuse include mishandling during manufacturing or transportation;
At this time, severe shock loads are applied to the motor. In order to investigate the effect of shock loading, a fixed composite horizontal structure of 23 parts and a conventional stator 2 part part with a cast iron frame fitted into the stator core were used in accordance with the embodiment of the present invention. I dropped it onto an iron block from a height of .20cm (4ft). After dropping it 11 times, about half of the subordinate stators were completely disassembled, and the cast iron frame came off from the stator iron 0.

Additionally, all stator windings were severed. On the contrary, the composite structure of the present invention has impact resistance and the stator windings did not break even after being dropped 70 times. In addition, there was no structural damage other than some scratches and some scraping on the outer surface. Furthermore, the motor equipped with the stator mechanism of the present invention exhibits at least the same effect as conventional motors in terms of suppressing or eliminating noise.

Noise tests were performed with several motors suspended from flexible elastic cords in an acoustically silent room. During each motor noise test, the motor was operated with no load and a microphone was placed approximately 15 skins (6 inches) from the noisiest part of the motor. The sound pressure of the noise generated by each motor was then recorded in decibels. The tests were conducted on 20 motors equipped with the stator mechanism of the present invention and 15 motors equipped with conventional cast iron frames. Data recorded and calculated values during these tests showed that the noise level of the conventional motor was not only louder but also irregular than that of the motor of the present invention. We measured the relative heat dissipation characteristics using the same test motor. The results show that although the motor of the present invention uses granular material (sand) in the fixed composite structure, and this sand is a good insulating material,
The temperature rise for a constant input in these motor outer shells was lower than the temperature rise in conventional motors. To explain in more detail, the motor of the present invention has a temperature of 0.8°C for every 1°C rise while the winding temperature is about 30qo higher than the ambient temperature.
79W was dissipated, whereas the conventional motor dissipated 0.763W for every 1°C rise in winding temperature. This data is 260
It was obtained by measuring the steady-state power that must be supplied to the motor to keep the windings at a steady-state temperature of 30 qo for an ambient temperature of ~40 pm. In addition to the winding temperature,
The steady temperature of the outer surface of the fixed composite structure was measured while the rotation of the rotor was restrained, and this was 1.
50qo, the temperature was 130°C for the subordinate motor. As is clear from the fact that the motor of the present invention can supply 15% more power than a conventional motor for a given rise in winding temperature, the heat dissipation of the stator core in the motor of the present invention is clear. The efficiency is 15% higher than that of the slave motor. At least part of the reason why the heat dissipation effect is simulated in the motor of the present invention is that the stator, stator windings, and the housing, which is a porous solid body made of particulate matter, are mechanically and closely connected over a wide area. This is thought to be due to contact. Furthermore, the possibility that the motor of the present invention will be attacked by rust or other corrosion is extremely small.

Next, one method for manufacturing a motor equipped with the stator mechanism of the present invention will be described in detail with reference to FIGS. 4 to 8.

First, a stator device consisting of a stator 61 and a stator winding 62 is mounted on a mold 6 which is supported in a shearing manner by a spring 66.
4 in the empty space 63. The spring 66 is fitted into the support 67 and surrounds a positioning boss 68 attached to the frame 69. Frame 69 is mold 6
It is fixed to 4. Place the stator device in the cavity 63 of the mold.
In order to create a space between the winding 62 and the bottom of the cavity 63 when the stator core 61 is inserted into the mold, the stator core 61 rests on a locking shoulder 71 made in the mold. There is. Next, a plug 72 having an outer surface corresponding to the center entrance of the composite structure shown in FIG. 8 is inserted into the center entrance of the stator core 61. A triangular plate 73 is fixed to the plug 72, and this plate 73 forms a recessed portion in the surface of the completed composite structure for the purpose described below. When the winding pin protrudes from the center opening, the tapered portion 72b of the plug 72 is used to move and hold the pin outside the entrance. After the core and windings are placed in the mold, a quantity of granular refractory material, such as sand, is dispensed between the mold 64 and the core 61 and windings 62.

The metering means comprises a hopper 74 and a metering dial which indicates when a predetermined amount of sand has been sent from the hopper 74 to the chute 77. A certain amount of sand 78 to fill the mold cavity 63 is supplied to three V-supply pipes 79a and 79b.
, 79c and fills the surroundings of the iron core 61, the mold 64 is filled with pipe plates 80a, 80
b, and sand is actively distributed and introduced into the gaps between adjacent winding coils and between the windings and the iron core. For pipe play, any commercially available product may be used. Note that the mold 64 is vibrated not only in the vertical direction but also in the horizontal direction. The pipelator 80a vibrates the mold 64 horizontally, and the pipelator 80b vibrates it vertically through horizontal plates 81a and 81b attached to the mold. When vibration is applied to the mold 64, sand also enters between the locking shoulder 71 in the mold and the stator core 61, forming a thin layer of sand. In this way, the stator core 64 is completely surrounded by the sand collection. After filling with sand, the mold 64 is moved to the injection site shown in FIG.

Therefore, a cover plate 82 having an air supply hole 83 and an adhesive supply hole 84 is attached to the mold 641 using set screws 88 and the like. Thereafter, a certain amount of adhesive is first injected into the mold from the adhesive reservoir 88 through the supply pipe 87. Glue 89 collects on the surface of the sand and seals the top of mold cavity 63. Although it is possible to allow the adhesive 89 injected into the mold to naturally penetrate into the gaps between the sand 78 due to its own weight, it is preferable to increase the pressure difference inside the filled sand 78 so that the adhesive 89 can be bonded. It is preferable to promote the penetration of the agent 89 into the sand.

Therefore, when the adhesive 89 accumulates on the surface of the sand 78 in the mold, a pressure of 28 to 42 k9/ground (4 to 6 psig) is applied to the inside of the mold through the pressure regulator 91.
supply air. This air pressure causes the adhesive 89 to move the sand 7
The sand and adhesive are forcibly injected into the gaps between the sand and adhesive. The air originally present in the gaps between the sand leaks out through the gap 92 between the end 72a of the plug 72 and the mold 64. The size of this gap 92 used as an air outlet is such that even if a pressure difference of 28 to 42 kg/ground is maintained between the inlet side and the outlet side of the mold, a large amount of sand and adhesive will remain inside. It is desirable that the tube be narrow enough to prevent leakage. When using the sand and adhesive described above with respect to the embodiment of FIG.
Use it as ribs. In order to induce a predetermined pressure difference inside the mold 64, it is desirable to apply a positive pressure to the inlet side of the mold, but by applying a negative pressure, that is, to create a vacuum condition, to the outlet side of the mold. can also create a predetermined pressure difference. Once the adhesive 89 has penetrated into the sand in the mold, it is cured or solidified to form a strong composite structure 93 with excellent impact resistance and heat dissipation properties as shown in FIG.

To do this, first remove the cover 82 and then remove the mold 6.
4 into the open 94 shown in FIG.
Heat to 19,000 for minutes. After 2g has passed, the sand inside the mold is solidified by the adhesive,
One solid composite structure 9 having a shape as shown in FIG.
3 can be removed from the mold 64.

The heating temperature and heating time listed above are just examples, and these may be changed as appropriate. A recess 95 in the solid composite structure 93 is created by the triangular plate 73, and a bearing support is placed within this recess 95, as will be described below.

Therefore, the shape of the recess 95 is not limited to a triangle;
It may be made in a shape that corresponds to the shape of the bearing support material to be attached. Once the solid composite structure 93 is formed as described above, the motor is then completed by combining it with other components.

To explain with reference to FIGS. 1 and 2, "After collecting the particulate matter and forming the solid composite structure 22 which is the housing of the motor, first, the rotor 2 is
9 to the bearing mechanism. Next, an epoxy resin 98 or other suitable adhesive is applied to the bearing support plate 24 or to the surface 99 of the composite structure 22 that contacts the bearing support plate 24. After that, the sim (
The bearing support plate 24 is fixed to the surface 99 while the rotor 29 is held at the center of the center entrance 39 by a screw (not shown). Once the epoxy resin 98 is fully cured, the shim is removed through the closure 34 in the bearing support plate 24. For this reason, the closing opening 34 is raised so as to align with the gap around the rotor 29 in all axial directions. Finally, cover the lubricating device with a mounting cover 28. This cover 28 is secured to the bearing support plate 24 by fitting the fasteners 36 into the openings 34, as previously described. After assembling the motor 20 in this way, clean the outer surface of the motor.
Prepare for coloring by performing etching, undercoating, etc.

Then apply paint etc. and let dry. Since the composite structure 22, which is the housing of the motor 20, is resistant to corrosive agents and is not adversely affected by water, it is not necessary to apply a protective coating thereto. Therefore,
In some cases, the above coloring and preparatory processes may be omitted altogether. Depending on the selection of the granular refractory material and/or adhesive used, the completed motor 20' can be given a desired color. For example, if chromite ore is used, the color of the housing or composite structure 22 will be black, if white sand is used, it will be almost white, and if brown river sand is used, the color will be beige. By adding dyes, pigments, etc. to the adhesive used, these become color-determining factors, allowing you to create a motor with the color of your choice. FIG. 9 illustrates another method of making a solid composite motor housing structure.

In the same figure, "The mold 121 consists of an upper mold 122 and a lower mold 123, which are connected to the clamp 12.
4 is held together. Mold 121 is motor 1
27 shaft 126. That is, the mold 121 is removably attached to the shaft 126 with screws 128 and is rotationally driven by a motor 127.
First, the stator core 129 to which the winding 131 and the terminal device 132 are integrally attached is placed in the lower mold 123. Next, the upper mold 122 is placed on the lower mold 123 and the two are fixed together with the clamp 124. do. When placing the upper mold on the lower mold, the terminal device 1
32 is made to protrude outside from the entrance 133 raised in the upper mold 122. Start the motor 127 and mold 121
When it starts to rotate at a predetermined speed, the movable particulate material supply nozzle 134 is lowered to the position shown in FIG. 9, and a predetermined amount of particulate material is discharged into the mold 121.

Furthermore, the movable adhesive supply pipe 136 is also lowered to the position shown in FIG. 9 to discharge adhesive into the mold 121. The rotation speed of the mold 121 may be appropriately changed depending on the type of granular material and adhesive used. 1st
When using the materials described with respect to the illustrated embodiment, good results are obtained when mold 121 is rotated at a speed of 160 pm.

Mold 121 with sand 138 and adhesive 137 rotating
While being simultaneously or substantially simultaneously discharged, heated air is applied to the mold 121 by the blower 139 to heat the mold. Centrifugal force is applied to the sand and adhesive in the mold by the rotational movement of the mold, and the sand and adhesive are applied to the wall of the mold 121, the stator iron ○ 129, and the winding 1.
31 and the terminal device 132. A predetermined amount of sand and adhesive are placed in the mold 12.
1, the supply nozzle 134 and the supply joint tube 136 are pulled up. During rotation of the mold, the adhesive 137 penetrates into the gaps between the sand 138. Rotation of the mold continues until the adhesive is sufficiently cured and the sand is consolidated and hardened enough to be removed from the mold. The solid body made of a large number of sands formed in this manner has the same shape as the solid body shown in FIG. In FIG. 9, sand 138 and adhesive 137 are supplied into the mold 121 at the same time, but the sand may be supplied first and then the adhesive.

In either case, the number of revolutions of the mold should be reduced to 6.0 while the sand and adhesive are being poured in the prescribed manner and the adhesive is curing.
to about 0 and pm. 10 to 13 show a motor equipped with a stator mechanism according to another embodiment of the present invention, and this motor 140 integrates a stator core 142, windings 143, terminals 144, 146, and particulate matter. The stator composite structure 141 includes a stator composite structure 141 and a housing.

A rotor 147 of known construction is attached to a shaft 148, and the shaft 148 is rotatably supported by a pair of bearings 149, 151. A thrust ring 152 is provided to absorb the end thrust generated during rotation of the motor.
, 153 are attached to the shaft 148, and this thrust ring cooperates with the bearings 149, 151 to eliminate the kojibata thrust. external oil covers 159, 161, bearing support plates 162, 163, and internal oil covers 164,
Oil chambers 157 and 158 are formed between the felt core 154 and a bearing lubricant such as oil. Supply pipes 167 and 168 are attached to the internal oil covers 164 and 166, respectively. In addition, well-known oil slingers 169', 170, 17 are attached to the shaft 148 to prevent loss of lubricating oil.
1a is installed. As can be seen from FIGS. 10 and 12, the bearing support members 162 and 163 are plates, and these bearing support plates 162 and 163 are bonded to the main components of the motor using thermosetting resin adhesive such as epoxy resin. It is fixed to end surfaces 172 and 173 of a housing 174, which is a member.

The housing 174 is a porous solid body formed by gathering and fixing particulate matter together with the iron core and the windings by the method described above. As shown in FIGS. 12 and 13, the fixed composite structure 1
41, the bearing support plate 163 is attached to the protrusion 1 on the front side.
76 so that the support plate 163 is attached to the front part 17
It is arranged to be supported at a distance from 7.

In this way, not only a space to reach the oil chamber 158 through the oil supply pipe 168 is secured, but also a flow path for sending cooling fluid such as air to the outside of the motor M is secured. A bearing support plate 162 is provided to facilitate the flow of cooling air into the motor and the removal of shims used to position the rotor.
, 163, a plurality of closing openings 179, 181 are spaced apart from each other and aligned with the space around the rotor in the crane direction.

These entrances 179, 181 are large enough to allow the shims to pass through, and form a passageway to the space around the rotor 147 in the same machine as the opening 34 in the motor of FIG. The rear surface of the composite structure 174 is also shaped so that the oil supply pipe 167 can be reached at a portion indicated by the reference numeral 182.

Although shield bolts 183 are shown in FIGS. 10 and 11 as a means of attaching the motor 40 to other suitable parts, it is of course possible to use other attachments. 14 and 15 show yet another embodiment of the invention, in which bearing support plates 201, 202 are secured to a housing portion of a stationary composite structure 206 using an adhesive.

The composite structure 206 is made by gathering and fixing particulate materials together as described above, and the functions of the fixing stop core 208, the winding 209, the oil reservoirs 211, 212, the oil covers 213, 214, etc. are all as described above. is the same as As shown in FIG. 15, end face 204 of composite structure 206 is designated by reference numeral 205.
The portion shown by is recessed, and the deformed head 216 of the mounting bolt 217 fits into this portion. The mounting bolts 217 are attached to the bearing support plate 20 by riveting or welding.
It may be fixed to 2. Also, as in the previously described embodiments, an opening 218 is provided for removing the shims used to position the rotor 219 within the central opening 221 during motor assembly. (See Figure 14). In the above embodiments, the bearing was attached to the end frame of the motor or the bearing support member that also serves as the end frame, but instead of using such separate bearings, the end frame itself could be used as a bearing. It's okay.

Furthermore, if fine particles are to be used as the granular material, ``even if the shape is irregular like the sand in the example described above, or even if it has the same shape, it does not matter.'' As detailed above, in the rotating electric machine of the present invention, a porous solid body is formed by solidifying chemically inert particulate matter and glass fibers together with a resin material and directly fixing them to the stator mechanism. The housing was made up of the following: The solid body making up the housing is not only substantially rigid itself, but also has impact resistance, heat dissipation properties, and self-retention properties.Particulate matter and glass fibers is chemically inert, so even if it is directly attached to the stator mechanism using a resin material, it will not corrode, oxidize, or otherwise cause chemical damage to the stator core, windings themselves, or their insulation coating. In the rotating electric machine of the present invention, the porous solid body made of solidified particulate matter and glass fibers is directly fixed to the stator mechanism, so that the housing and the stator mechanism are not connected to each other. It has an integrated structure,
It is mechanically stable and has excellent strength. Further, since the solid housing made of particulate material and glass fiber is directly and integrally fixed to the stator mechanism, the heat generated by the stator mechanism during operation is rapidly radiated to the outside through the housing. In particular, since the entire housing, which is directly and integrally fixed to the stator mechanism, acts as a heat sink, the rotating electric machine of the present invention has extremely good heat dissipation properties, and the temperature hardly rises during operation. do not have. Heat does not accumulate in the internal space where the rotor is housed. Furthermore, since the stator mechanism and housing have an integrated structure, vibrations are not easily generated during operation, and the housing is made of inert particulate matter and glass fibers solidified with resin, making it easier to rotate. It also has the effect of suppressing noise generation by absorbing vibrations during operation of the bearing device and the bearing device that supports it. Therefore, the operating sound of the rotating electric machine of the present invention is much quieter than that of the same type of rotating electric machine having a conventional metal housing, and it can be used in a wide range of applications where silence is required. The solid body mainly composed of inert particulate matter and glass fiber that constitutes the housing is directly fixed to the stator mechanism, and the housing and stator mechanism are structurally integrated, making it possible to There is no need to attach a separate housing or metal frame to the outside of the stator, which not only simplifies the structure but also makes the external shape more compact. When compacting only the particulate material to form a porous solid, at least 5% by weight of the particulate material is packed with a particle size of 40 mesh or more.
If 100 mesh is selected and used, the resulting porous solid will have a delicate structure, and when the voids are filled with resin adhesive and solidified, it will become a substantially rigid solid member. It has sufficient self-retention properties and sufficient mechanical strength without any metal envelope, and there is no risk of particulate matter missing and interfering with rotor operation. Furthermore, sufficient heat dissipation properties can be provided.

However, if the majority of the granular material is smaller than 100 mesh, the voids of the porous solid formed by compacting the granular materials will become significantly smaller by q, making it impossible to fill the voids with resin, which makes it impossible to fill the voids with the resin. cannot form a consolidated solid body with the desired structural integrity. Alternatively, even if an aggregated solid body is formed, cracks or surface cracks will occur in the aggregated solid body after the resin adhesive has hardened, resulting in a significant decrease in mechanical strength. In contrast, in the present invention, since glass fibers are used together with inert particulate matter to form a solid body, all or a significant portion (50% or more) of the particulate material is thinner than 100 mesh. Nevertheless, it is possible to ensure sufficient mechanical strength, sufficient self-formability without a metal jacket, and good heat dissipation without losing the above-mentioned benefits.

[Brief explanation of the drawing]

Fig. 1 is a rear view of a motor equipped with a stator mechanism according to an embodiment of the present invention, Fig. 2 is a sectional view taken along line 2-2 in Fig. 1, and Fig. 3 is a diagram shown in Fig. 1. Reproductions of micrographs showing the surface weave of the fixed composite structure part of the motor, Nos. 4, 5,
6 and 7 are views showing the method used to manufacture the motor shown in FIG. 1, FIG. 8 is a perspective view of a stationary composite machine structure manufactured by the method shown in FIGS. 10 is a rear view of a motor equipped with a stator mechanism according to another embodiment of the present invention; FIG.
The figure is a cross-sectional view taken along line 11-11 in Figure 10,
Fig. 12 is a partial front view of the motor shown in Fig. 10, Fig. 13 is a sectional view taken along line 13-13 in Fig. 12,
FIG. 4 is a rear view of a motor equipped with a stator mechanism according to yet another embodiment of the present invention, and FIG.
FIG. 3 is a cross-sectional view taken along a line. 20...Motor, 22...
・Composite structure, 24... Bearing support plate, 28.
......Cover, 29...Rotor, 37...
...Stator, 41... Winding wire, 43... Conductive terminal, 96, 97... Stop washer. FIG. 14 F'16.15 f'6.Z FIG.3 F'G.9 'U○〃 〆'G.

Claims (1)

[Claims] 1 Consisting of a magnetic core, at least one electric winding disposed on the magnetic core, and a housing that accommodates at least a portion of the at least one electric winding and supports a rotor member therein, the housing is made of resin. a porous solid body of material and an inert material, said inert material comprising particulate material compacted together and in substantial contact with each other, said particulate material comprising said magnetic core and electrical windings; is compacted and fixed to at least a portion of at least one of said porous solids to constitute one substantially rigid, self-retaining solid member having no metal envelope; The amount of resinous material is sufficient to substantially fill the voids in the solid body, all or a significant portion of the particulate material is finer than 100 mesh, and the inert material further includes glass fibers. This protects at least a portion of at least one of the magnetic core and the electric winding from mechanical damage, dissipates heat generated during excitation of the winding, and prevents the rotation with respect to the magnetic core. A stator mechanism for an electric motor, characterized in that it supports a child member.