KR100919992B1 - Stator assembly and production method of stator assembly - Google Patents

Abstract

PURPOSE: A stator assembly and a manufacturing method thereof are provided to avoid interference of a rotor and a frame assembled into an external diameter side. CONSTITUTION: A plurality of twisting parts and a twisting section are consecutively formed by twisting a wire of a rectangular shape as 90 degree(S10). A straight line part and a forming part are consecutively formed by forming the wire between the twisting parts as the same gap(S20). The straight line part is inserted to a stator core slot. The forming part is exposed outside the stator core slot(S30). A plurality of wires are laminated in the stator core slot(S40).

Description

Stator assembly and stator assembly manufacturing method {STATOR ASSEMBLY AND PRODUCTION METHOD OF STATOR ASSEMBLY}

The present invention relates to a stator assembly and a stator assembly manufacturing method, and to a stator assembly and a stator assembly manufacturing method in which an alternating voltage is induced by the rotation of a magnetized rotor of an automotive alternator.

The vehicle may be equipped with various types of electronic devices, and a generator and a storage battery are provided inside the vehicle for supplying power to the electronic devices.

Types of generators include a DC generator and an alternator. In general, an alternator that maintains stability at low and high speeds is more widely used than a DC generator.

As shown in FIG. 8, the vehicle alternator is rotatably disposed in the center of the housing 100 to generate a magnetomotive force, and a rotor assembly 110 and the rotor assembly. and a brush assembly 120 for supplying current to the assembly 110 and surrounding the rotor assembly 110 along the inner circumferential surface of the housing 100. Maintaining a stator assembly 130 that generates induced electromotive force by the magnetic force and the voltage generated in the rotor assembly 110 and the stator assembly 130 in a constant state Receives power from a voltage regulator (140), a rectifier (150) for rectifying the alternating current (AC) adjusted in the voltage regulator (regulator) 140 to a direct current (DC) As It is configured to include a pulley 160 that is connected via the spirit crankshaft and the belt.

The rotor assembly 110 is attached to a generally cylindrical shaft, the cylindrical shaft being rotatably mounted to the housing 100 and coaxial with the rotor assembly 110.

In addition, the stator assembly 130 is mounted to the housing 100, and includes a generally cylindrical stator core having a plurality of slots formed on an inner circumferential surface thereof, and a plurality of wire coils wound on the stator core to form a winding.

The wire coil of the related art is made of a wire 30 whose cross section is round as shown in FIG. 9, and the circular shape of the wire 30 is a dead zone in the stator core slot. There is a limit to increasing the fill-factor by generating. Therefore, there is a problem in that it is an obstacle to increase the output and efficiency of the vehicle alternator.

In addition, when a plurality of wires 30 having a round cross section are inserted into the stator core slots, the stack thickness of the wires 30 exposed to the outside of the stator cores is inserted into the stator core slots. It may be formed to be the same as the thickness of the laminate, which is a problem that can be interfered by the rotor (rotator) rotating in the inner diameter of the stator assembly and the frame (frame) assembled at the outer diameter.

Therefore, it is possible to generate high power and high efficiency in the generator by preventing the generation of dead zone in the stator core slot and increasing the fill-factor, and also the rotor and the frame. Changes in the stator assembly are required to avoid interference.

The present invention has been made to solve the above problems, the stator core to prevent the generation of dead zones (dead zone) in the rise (fill-factor) to increase the fill (factor), thereby generating a high output and high efficiency It is an object of the present invention to provide a method for manufacturing an assembly and a stator assembly.

Another object of the present invention is to provide a stator assembly and a stator assembly manufacturing method which can avoid interference of a rotating rotor and also avoid interference of a frame assembled to an outer diameter.

The stator assembly manufacturing method according to the present invention to achieve the object as described above is a twisting step of forming a twisting portion by twisting a wire having a rectangular cross section (rectangular), and the wire between the twisting portion Forming a straight portion and a forming portion on the wire by forming the upper and lower parts at the same interval, and inserting the straight portion into the stator core slot, and inserting the forming portion to the upper and lower portions of the stator core slot. And a wire stacking step of stacking a plurality of wires formed with a straight portion and a forming portion in the stator core slots.

The twisting part may be formed by twisting the wire at an angle of 90 °.

The twisting part may be twisted in the same direction so that the same surface of the wire may continuously appear in the forming part.

The twisting part may be twisted in different directions so that one side and the other side of the wire appear alternately in the forming part.

In addition, the stator assembly according to the present invention includes a stator core having a plurality of stator core slots formed on an inner circumferential surface thereof and a plurality of wire coils inserted into the stator core slots, wherein the wire coils have a rectangular cross section. (rectangular) wire, the wire between the twisting portion formed in the wire is formed in the upper and lower (forming) at the same interval (forming) exposed to the upper and lower portions of the stator core slot, and a straight line inserted into the stator core slot It may be configured to include a part. In this case, the twisting portion may be formed by twisting the wire at an angle of 90 °.

In addition, the stacking thickness of the narrow surfaces of the forming portion may be formed smaller than the stacking thickness of the wide surfaces of the straight portion in the stator core slot.

According to the stator assembly and the stator assembly manufacturing method according to the present invention as described above to prevent the generation of dead zones in the stator core slot to increase the fill-factor, thereby generating high power and high efficiency It works.

Another effect of the present invention is that the wire stacking thickness outside the stator core by twisting is formed smaller than the wire stacking thickness in the stator core slot, so that interference of the rotor can be avoided, and the frame assembled to the outer diameter ( frame interference) can also be avoided.

Hereinafter, with reference to the accompanying drawings will be described an embodiment of the present invention; First, it should be noted that the same components or parts in the drawings represent the same reference numerals as much as possible. In describing the present invention, detailed descriptions of related well-known functions or configurations are omitted in order not to obscure the gist of the present invention.

1 is a block diagram of a stator assembly manufacturing method according to an embodiment of the present invention, Figures 2a and 2b is a perspective view of the wire for the stator assembly, Figures 3a, 3b and 3c is a twisted stator It is an illustration of the wire for assembly. 4 is a view showing a forming shape of a stator assembly wire according to an embodiment of the present invention, and FIGS. 5A to 5C show the stator assembly wires of FIGS. 3A, 3B, and 3C, respectively. 6A to 6B are enlarged views of a forming shape, and FIGS. 6A to 6B show a structure in which a wire for stator assembly is inserted into a stator core slot. In addition, Figure 7a is a view showing a stator assembly according to an embodiment of the present invention, Figure 7b is a partial enlarged view of the wire coil of Figure 7a, Figure 8 is a cross-sectional view of a vehicle alternator. 9 is a perspective view of a conventional stator assembly wire.

Stator assembly manufacturing method according to an embodiment of the present invention, as shown in Figure 1, the twisting step (S10), forming step (S20), wire insertion step (S30), wire lamination step (S40) It is configured to include.

The twisting step (S10) is a step of forming a twisting part by twisting a wire 10 having a rectangular cross section as shown in FIG. 2A.

Since the wire 10 has a rectangular cross section, a wide surface and a narrow surface are configured.

Specifically, the wide face is the A face and the A 'face, and the narrow face is the B face and the B' face. In this case, the A plane is the same as the A 'plane, the B plane is the same as the B' plane, and the A plane and the A 'plane are larger than the B plane and the B' plane.

The wire 10 having a rectangular cross section is sequentially inserted and stacked in the stator core slot, which will be described later, to prevent the occurrence of dead zones in the stator core slot to increase the fill factor. As a result, high power and high efficiency can be generated in the generator.

As shown in FIG. 2B, the wire 10 may have a rectangular cross section, but may be configured such that the corners of each copper line have a round shape in consideration of productivity and quality.

As shown in FIGS. 3A, 3B, and 3C, the twisting part may be formed on the wire 10 by twisting the wire 10 at an angle of 90 °.

In addition, the twisting part 11 may be twisted in the same direction so that the same surface of the wire 10 may be continuously formed in the forming part of the wire 10 to be described later.

Specifically, the twisting section is configured in one direction, and as shown in FIG. 3A, the A ′ surface 10b may be continuously displayed upward between the twisting units 11. As shown in FIG. 3B, the A surface 10a may be configured to appear upward continuously.

In addition, the twisting part 11 may be twisted in different directions so that one surface and the other surface of the wire 10 appear alternately in the forming part.

Specifically, it is configured by alternately twisting (twisting) section, as shown in Figure 3c, the A surface (10a) and the A 'surface (10b) between the twisting portion 11 A' surface (10b) ), A surface 10a, A 'surface (10b) can be configured to appear alternately in order.

The forming step S20 is performed between the twisting parts 11 as shown in FIG. 4 before inserting the twisted wire 10 in the twisting step S10 into the stator core slot. A step of forming the straight portion 12 and the forming portion 13 on the wire 10 by forming the wire up and down at the same interval.

As shown in FIG. 6A, the straight portion 12 is a portion to be inserted into the stator core slot 21 formed on the inner circumferential surface of the stator core 20 and should be larger than the slot height 23 of the stator core. .

In addition, the forming unit 13 is a portion that is exposed to the outside of the stator core 20 up and down, it may vary depending on the size of the stator (stator).

In the forming step (S20), the A surface 10a as shown in FIG. 5A, which is a wide surface between the twisting portions 11, or the A 'surface 10b as shown in FIG. 5B, is always in the same direction. It may be formed to appear, and the A surface 10a and the A 'surface 10b as shown in FIG. 5C may be alternately formed.

As shown in FIG. 6A, the wire insertion step S30 inserts the straight portion 12 formed in the forming step S20 into the stator core slot 21, and the forming part 13 includes the Exposure to the upper and lower parts of the stator core slot 21.

In the wire insertion step S30, as shown in FIGS. 3A, 3B, and 3C, the B surface or B ′ which is a narrow surface of the wire 10 by the twisting part 11 formed on the wire 10. A surface and a wide surface A surface 10a or A 'surface 10b are inserted into the stator core slot 21 while maintaining a direction difference of 90 degrees.

Specifically, as shown in FIG. 6B, the B surface 10c or the B 'surface (not shown), which is the narrower surface of the straight portion 12 of the wire 10, toward the narrow width of the stator core slot 21. It is inserted, it can be configured such that the B surface (10c) or the B 'surface (not shown), which is a narrow surface of the forming portion 13 of the wire 10 in the upper and lower exposure section of the stator core 20.

In the wire stacking step (S40), a plurality of wires 10 having the straight portion 12 and the forming portion 13 are sequentially inserted and stacked in the stator core slot 21.

In the wire stacking step (S40), an A surface 10a or an A 'surface (not shown), which is a wide surface of the wire, is inserted toward the depth 22 of the stator core slot, and the A surface 10a or A' surface is inserted. Based on (not shown), the straight portions 12 of the wire are sequentially stacked.

In addition, a B surface 10c or a B 'surface (not shown), which is a narrow surface of the wire, appears in the vertical direction in the vertical exposure section of the stator core 20, and the forming portions 13 of the wires are stacked, and FIG. 7A. And a stator assembly as shown in FIG. 7B.

Meanwhile, the stack thickness 24 of the narrow surfaces of the wires exposed above and below the stator core 20 may be smaller than the depth 22 of the stator core slot.

Specifically, the stacking thickness 24 of the forming unit 13 may be smaller than the stacking thickness of the straight portion 12 in the stator core slot 21. Therefore, interference of a rotor rotating in the inner diameter of the stator assembly may be avoided, and interference of a frame assembled toward the outer diameter may be avoided.

Hereinafter, a stator assembly according to an embodiment of the present invention will be described in detail.

The stator assembly according to an embodiment of the present invention comprises a stator core and a plurality of wire coils.

As shown in FIG. 6B, the stator core has a cylindrical shape, and a plurality of stator core slots 21 into which the wire coil is inserted are formed at regular intervals.

As shown in FIGS. 2A to 2B, the wire coil has a rectangular cross section, and as shown in FIGS. 3A, 3B, and 3C, a portion of the wire coil is twisted to form a plurality of twisting parts. 11 is formed of a wire 10, wherein the twisting portion 11 may be formed by twisting the wire 10 at a 90 ° angle.

The twisting part 11 may be formed by the same method as the method for forming the twisting part described above in the twisting step of the stator assembly manufacturing method according to an embodiment of the present invention.

In addition, the wire coil is formed up and down as shown in Figure 4, the wire 10 between the twisting portion 11, as shown in Figure 6a to 6b, the stator core slot ( 21 and a straight portion 12 inserted into the stator core slot 21.

The straight portion 12 and the forming portion 13 of the wire coil are a B surface 10c or a B 'surface (not shown), which is a narrow surface of the wire 10 by a twisting portion 11 formed in the wire coil. And, A surface 10a or A 'surface (not shown), which is a wide surface, maintains a direction difference spaced at an angle of 90 °, and is sequentially inserted and stacked in the stator core slot 21.

Therefore, the lamination thickness 24 of the narrow surfaces of the forming portion 13 exposed to the upper and lower sides of the stator core 20 is the lamination thickness of the wide surfaces of the straight portion 12 in the stator core slot 21. The stator assembly may be formed to be smaller than the depth 22 of the stator core slot to avoid interference between the rotor and the frame.

Hereinafter, the operation of the stator assembly and the stator assembly manufacturing method according to an embodiment of the present invention.

As shown in Fig. 9, the wire coil inserted into the stator core slot in the automotive alternator is rectangular instead of the conventional wire 30 due to the cross section, as shown in Figs. 2A to 2B. By forming the wire 10), it is possible to prevent the occurrence of dead zones in the stator core slots and to increase the fill-factor, thereby increasing the output and efficiency of the generator.

In addition, a twisted wire 10 having a rectangular cross section is formed at an angle of 90 ° to form a plurality of twisting parts, and then a forming part exposed to the wire 10 above and below the stator core, and the stator. A straight portion inserted into the core slot is formed, but as shown in FIG. 6B, the stacking thickness 24 of the narrow surfaces of the forming portion 13 has a large width of the straight portion 12 stacked in the stator core slot 21. By sequentially inserting and laminating the wires so as to be smaller than the stacking thickness of the surfaces, interference between a rotor rotating at the inner diameter of the stator assembly and a frame housed at the outer diameter can be avoided.

As described above with reference to the drawings illustrating a stator assembly and a stator assembly manufacturing method according to the present invention, the present invention is not limited by the embodiments and drawings disclosed herein, it is within the technical scope of the present invention Of course, various modifications can be made by those skilled in the art.

1 is a block diagram of a stator assembly manufacturing method according to an embodiment of the present invention.

Figure 2a is a perspective view of a wire for the stator assembly according to an embodiment of the present invention.

Figure 2b is another perspective view of the wire for the stator assembly according to an embodiment of the present invention.

3A illustrates one embodiment of a twisted stator assembly wire in accordance with one embodiment of the present invention.

3B illustrates another embodiment of a twisted stator assembly wire in accordance with one embodiment of the present invention.

3C is another embodiment of a twisted stator assembly wire in accordance with one embodiment of the present invention.

4 is a view showing a forming shape of the wire for the stator assembly according to an embodiment of the present invention.

5A is an enlarged view of a forming shape using the stator assembly wire of FIG. 3A.

5B is an enlarged view of a forming shape using the stator assembly wire of FIG. 3B.

5C is an enlarged view of a forming shape using the stator assembly wire of FIG. 3C.

6A to 6B are views illustrating a structure in which a wire for a stator assembly is inserted into a stator core slot according to an embodiment of the present invention.

7A illustrates a stator assembly in accordance with one embodiment of the present invention.

FIG. 7B is an enlarged partial view of the wire coil of FIG. 7A. FIG.

8 is a cross-sectional view of a vehicle alternator.

9 is a perspective view of a wire for a conventional stator assembly.

<Description of Symbols for Main Parts of Drawings>

S10: twisting step S20: forming step

S30: wire insertion step S40: wire stacking step

10: Wire 10a: A side

10b: A 'plane 10c: B plane

11: Twisting part 12: Straight part

13: Forming part 20: Stator core

21: Stator core slot 22: Stator core slot depth

23: Stator core slot height 24: Lamination thickness of the forming portion

30: conventional wire 100: housing

110: rotor assembly 120: brush assembly

130: stator assembly 140: voltage regulator

150: rectifier 160: pulley

Claims (7)

A twisting step of continuously twisting a wire having a rectangular cross section at an angle of 90 ° to continuously form a plurality of twisting sections and a twisting section between the twisting sections; Forming a wire between the twisting portions at the same interval by vertically forming a straight portion inserted into the stator core slot and a forming portion exposed up and down outside the stator core slot; A wire insertion step of inserting the straight portion into the stator core slot and exposing the forming part up and down outside the stator core slot; And And a wire laminating step of stacking a plurality of wires formed in succession of the straight line portion and the forming portion in the stator core slots. delete The method of claim 1, The twisting portion is twisted in the same direction (twisting) is a stator assembly manufacturing method characterized in that the same surface of the wire is configured to appear continuously in the forming portion. The method of claim 1, The twisting unit is twisted (twisting) in different directions so that one side and the other side of the wire alternately continuously appear in the forming unit. A stator assembly comprising a stator core having a plurality of stator core slots formed on an inner circumferential surface thereof, and a plurality of wire coils inserted into the stator core slots. The wire coil is made of a wire having a rectangular cross section, and the wires between the plurality of twisting parts formed by twisting the wires at 90 ° angles are vertically formed at equal intervals so that the stator A stator assembly, characterized in that the forming portion is exposed to the outside of the core slot up and down and the straight portion inserted into the stator core slot is formed continuously. delete The method of claim 5, Stator assembly characterized in that the laminated thickness of the narrow side of the forming portion is smaller than the laminated thickness of the wide side of the straight portion in the stator core slot.

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