KR102013853B1 - Method for producing laminated stator and generator and motor including thereof - Google Patents

Abstract

The present invention relates to a stacked stator and a manufacturing method of a generator and a motor including the same. The manufacturing method of a generator and a motor comprises: a step of cutting an electric steel plate into a circular shape; a step of cutting into an octagonal shape combined with lines and arcs; a step of forming a first and a second heat radiation unit; a third heat radiation unit forming step; a step of machining a single electric steel plate including an installation hole forming step; a step of repeating the step of machining a single electric steel plate to machine at least a thousand electric steel plates, and rotating the machined electric steel plates by a prescribed angle to stack the electric steel plates; a step of forming a groove on each electric steel plate; and a step of welding the groove. According to the present invention, an area where corners of disks making up the stacked stator are exposed becomes wider to improve heat radiation effects. The heat radiation units of the disks making up the stacked stator are stacked, communicate with each other, and consequently penetrate the entire rotor to circulate air through the heat radiation units. The grooves for welding are on the disks making up the stacked stator to maintain a stacked state of the entire rotor to simplify the structure and save installation space.

Description

Stacking stator and method for manufacturing generator and motor having same {METHOD FOR PRODUCING LAMINATED STATOR AND GENERATOR AND MOTOR INCLUDING THEREOF}

The present invention relates to a stator in which disks are stacked in a generator or a motor, and more particularly, to a method of manufacturing a generator and a motor having a laminated stator having an improved circular disk.

In general, a generator that generates electromotive force by electromagnetic induction and converts mechanical energy into electrical energy and a motor that generates mechanical driving force by using electrical energy basically has a cylindrical stator, that is, stator, which is fixedly installed on the inner wall of the housing. The rotor is installed inside the stator and the stator and is rotated by the rotor shaft and induces power generation in the stator during rotation.

The existing stator basically has a structure in which a rotor is inserted therein in a state in which disc-shaped discs are stacked in front and rear. This stator must have its own heat dissipation structure because the stator is continuously generated by electrical reactions during the rotation of the rotor. However, as described above, since the original disks are all disks having the same area, the heat dissipation effect is not good because all the areas are in close contact with each other in the stacked state.

On the other hand, the conventional stator is located in the housing in the support rod is located on the outer circumferential surface all around, and by installing a separate support frame on both ends of the stator, the position is fixed as well as the state of the stack is maintained as the support frame is connected to each support rod fixed . However, the support rod is inserted into the gap between the housing and the stator outer circumferential surface. At this time, the gap between the stator and the housing is quite narrow, so it is difficult to insert the support rod. In addition, since the support frame must be made larger than the diameter of the stator, it is inevitably required to make the size of the housing unnecessarily large so that the support frame can be accommodated. Therefore, there is a problem that causes a waste of space. In addition, the support rod and the support frame are structures that are inevitably provided in order to maintain the stacking state of the stator, and have no relation to power generation efficiency or heat dissipation efficiency. Korean Patent No. 10-0933049 is an example of a structure to which such a general stacked stator is applied.

Domestic Patent No. 10-0933049 (2009.05.12.)

The technical problem of the present invention is to provide a laminated stator which can obtain a self-improved heat dissipation effect in a laminated state by improving the structure of the original plate, and to provide a generator and a motor having a lower heat generation based on this.

Another technical problem of the present invention is to provide a laminated stator, a generator, and a motor that can reduce the internal space as well as simplify the installation structure by combining the stator with the housing without a separate connection.

According to one aspect of the present invention, a step of rotating a 0.5 mm thick rectangular steel sheet is cut out in a circular shape using a cutter, and cuts the upper, lower, left, and right sides of the circular electrical steel sheet to form a straight line on the 1st, 3rd, 5th and 7th sides. And forming octagons having arcs of constant curvature in the second, fourth, sixth, and eighth sides, and forming a plurality of heat dissipation fins so as to be symmetrical on both sides of the reference line which bisects an angle between adjacent middle points from the center point of the electrical steel sheet. The point that is twisted 15 ° on both sides with respect to the step and the reference line is to be the end point of both sides of the 2nd, 4th, 6th, and 8th arc-shaped slopes, and the angle between both ends of the sloped surface is 30 ° with respect to the center point. Forming the first and second heat dissipation fins at the symmetrical positions of the first and second heat dissipation fins, and forming the third heat dissipation fins so that the first and second heat dissipation fins are exposed from the front disc and communicate with each other back and forth while being stacked. The hem includes the steps of forming an installation hole in which the insertion groove into which the stator winding is inserted is formed in the rim at intervals that can be communicated with the insertion groove of the other disc. The electrical steel sheet is processed by processing at least a thousand electrical steel sheets, and a plurality of electrical layers are repeatedly performed by laminating a plurality of electrical steel sheets by rotating them in a clockwise direction by 30 ° from the lower side to the upper side of the processed electrical steel sheets. Stacking the steel sheets and forming grooves at the midpoints of each inclined surface of each electrical steel sheet to face the center point, the depth of the grooves so that the distance from the center point to the bottom surface of the grooves and the distance from the midpoint of the outer line segment are equal Forming and welding the formed grooves characterized in that for manufacturing a plurality of electrical steel sheet laminated stator Provided is a stacked stator manufacturing method comprising a stacked stator forming step.

According to the present invention, the area exposed by the edges of the original plate constituting the stacked stator can be widened to increase the heat dissipation effect.

According to the present invention, the heat dissipation parts of the original plates constituting the stacked stator communicate with each other in a stacked state, and thus, may pass through the entire rotor to circulate air through the heat dissipation part.

According to the present invention, the lamination state of the whole rotor can be maintained in the original groove constituting the laminated stator, so that the structure can be simplified and the installation space can be saved.

1 is a flowchart illustrating an example of a method of manufacturing a stacked stator and a generator and a motor including the same according to the present invention.
Figure 2 is an example showing the bonding of the stator laminated in accordance with the present invention.
3 is a view from above of an example of electrical steel sheets laminated according to the present invention;

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. In addition, in order to clearly disclose the present invention, parts not related to the present invention are omitted, and the same or similar reference numerals denote the same or similar elements in the drawings.

The objects and effects of the present invention may be naturally understood or more apparent from the following description, and the objects and effects of the present invention are not limited only by the following description.

The objects, features and advantages of the present invention will become more apparent from the following detailed description. In addition, in describing the present invention, when it is determined that the detailed description of the known technology related to the present invention may unnecessarily obscure the subject matter of the present invention, the detailed description thereof will be omitted. Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Now, a method of manufacturing a stacked stator and a generator and a motor having the same will be described.

When the electrical steel sheets are rotated and stacked, the entire stator is manufactured to have a circular shape. An inclined surface is formed on the outer circumferential surface of the manufactured laminated stator, and three heat dissipating portions are formed through the heat dissipation portion to increase heat dissipation efficiency near the corner portion where the inclined surface is formed. There is an effect of increasing the surface area where heat is radiated, and the stator itself has a heat dissipation effect.

1 is a flowchart illustrating an example of a method of manufacturing a stacked stator and a generator and a motor including the same according to the present invention.

Referring to FIG. 1, the stacked stator manufacturing method includes an electrical steel sheet forming step S110 and a stacked stator forming step S120.

Forming one electrical steel sheet (S110); rotating the electrical steel sheet having a square shape of 0.5 mm thickness by cutting the circular steel sheet using a cutter; Cutting the upper, lower, left, and right sides of the circular electrical steel sheet to form an octagon in which the 1st, 3rd, 5th, and 7th sides are straight, and the 2nd, 4th, 6th, and 8th sides are arcs of a certain curvature; Respectively forming a plurality of heat dissipation fins so as to be symmetrical on both sides of a reference line dividing an angle between adjacent mid points from a center point of the electrical steel sheet; 15 degrees to both sides with respect to the reference line to be both end points of the inclined surfaces of the second, fourth, sixth, and eighth arcs, and an angle between the two end points of the inclined surfaces forms 30 degrees from the center point. Forming first and second heat dissipation fins at positions symmetrically symmetric with respect to the reference line, and forming third heat dissipation fins so as to be in communication with each other back and forth while being exposed from the front disc when stacked; And forming an installation hole formed in the center of the electrical steel sheet at an interval at which the insertion groove into which the stator winding is inserted may be communicated with the insertion groove of the elliptical plate.

Stacked stator forming step (S120) is formed by at least a thousand of the electrical steel sheet, and repeatedly performed by laminating by rotating in a clockwise direction 30 ° than the previous electrical steel sheet from the bottom to the upper direction of the formed electrical steel sheet Stacking electrical steel sheets; and forming grooves at the middle points of the inclined surfaces of the respective electrical steel plates so as to face the center points; Forming a depth of the groove so that a distance from a center point to a bottom surface of the groove is equal to a distance from an intermediate point of the outer line segment; And forming the plurality of electrical steel sheets into a laminated stator by welding the formed recesses.

According to the present invention, the generator and the motor manufacturing method includes an electric steel sheet forming step (S110) and stacked stator forming step (S120) as well as a core forming step (S130) and a generator and motor manufacturing step (S140).

The core forming step (S130) may include: a winding step of forming a winding including a pair of predetermined parts in the slot corresponding to the in-slot arranging part and a pair of coil end predetermined parts corresponding to the coil end arranging part; A convex forming step of forming the coil end predetermined part into a convex shape protruding in the circumferential direction of the winding; A crank forming step of forming a step size of the width of the conductor in the stacking direction of the conductor in the coil end scheduled portion; An open molding step of molding such that the distance between the predetermined portions in the pair of slots is gradually increased with respect to the stacking direction of the conductors; An arc forming step of forming an arc-shaped portion that curves in the stacking direction of the conductor in one or both of the pair of coil end scheduled portions; And the winding step such that the stacking direction of the conductors in one coil end planar part and the stacking direction of the conductors in the other coil end planar part are perpendicular to each other with respect to the pair of coil end scheduled parts. And a 90 ° bending forming step of performing bending forming on the formed winding.

Generator and motor manufacturing step (S140) includes the step of connecting the grooves of the formed stacked stator in contact with the housing, comprising the step of providing the core inside the housing so as to interlock with the stacked stator.

As another example, the groove of the stator may form a ventilation path having a branch path for branching the flow in the direction of the center point.

As another example, the core forming step may include mounting an insulator including a first slot into which a first power terminal is inserted and a second slot into which a neutral terminal is inserted into a stator core having a plurality of teeth formed radially. The method may further include winding the coil. The core forming step may include an upper insulator covering and insulating the upper portion of the tooth, an upper insulator having an upper coupling portion formed inwardly, and having an upper coupling hole formed therein, and a lower portion covering the lower portion of the tooth and formed inwardly and having a lower coupling hole formed therein. A lower insulator having a coupling portion, a coil wound between the upper insulator and the lower insulator covered by the insulated tooth portion and connected between adjacent teeth and a coil connected between the adjacent teeth so that the coil is not exposed to the outside. The method may further include providing a coil protective cover covering the upper portion of the portion.

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Figure 2 is an example showing the bonding of the stator laminated in accordance with the present invention.

Referring to FIG. 2, the electrical steel sheets 100, 200, 300, and 400 constituting the stator 1000 are manufactured from a rectangular plate shape. The inclined surfaces 122, 124, 126, and 128 are formed at each point where the line segments 110 of the outer edge meet. These inclined surfaces have an octagonal shape. Through such inclined surfaces, the entire stator becomes a circular shape when the electrical steel sheets are rotated and stacked. The laminated stator can fully react with the rotation of the rotor. Therefore, the inclined surface has a certain curvature arc shape rather than a straight line shape. Each electrical steel sheet (100, 200, 300) constituting the stator is produced in an octagonal shape, but are sequentially rotated while being increased by a predetermined angle so that the corners, that is, the inclined surfaces of the electrical steel sheets (100, 200, 300) all protrude outwards. Thus, the heat dissipation area can be secured.

In addition, it is another feature that the heat dissipation efficiency can be further increased by forming a moving path of the air by the heat dissipating portion communicating with each other during the lamination process.

In addition, by improving the structure of each of the electrical steel sheet to enable the mutual connection, it is also characterized in that it can be installed without a separate support rod and support frame.

The basic structure of manufacturing the electrical steel sheet in a square shape and laminating it sequentially by a predetermined angle is the same as in the previous embodiment, but there is a difference in that it is superposed without forming an inclined surface at an edge portion of the electrical steel sheet.

Therefore, this structure also has a corner portion protruding to the outside. Of course, in this case, the exterior is not circular when viewed from the front, but the space charge in the case is relatively large. However, a large area is protruded compared to the case where the inclined surface is formed. have.

3 is a view from above of an example of electrical steel sheets laminated according to the present invention;

Referring to FIG. 3, when viewed from the front in a laminated state, each electrical steel sheet is accurately connected without overlapping to form a circle.

The electrical steel sheet is square. At this time, the angle between the center point of the electrical steel sheet and the intermediate point of each outline is 90 degrees. It is assumed that the angle between the midpoint and the adjacent midpoint is at an angle bisecting, i.

The 15 ° twisted sides of the baseline should be the end points of both sides of the slope. At this time, the angle between both end points of the inclined surface forms 30 ° with respect to the center point. The length and angle of the inclined surface are formed at an angle corresponding to one third of the angle between the outlines.

However, the above-described angle setting method between the both ends of the inclined surface is equally applicable to the case where the electrical steel sheet is a polygon other than a square.

The heat radiation unit 130 is formed to increase heat radiation efficiency near each corner portion in which the inclined surface 122 is formed, and the heat radiation unit 130 is first and second at a point inclined 15 ° to the left and right with respect to the reference line. The heat dissipation parts 132 and 134 are formed to be divided so that the angle between the center points of the first and second heat dissipation parts 132 and 134 is also 30 °.

The angles between the heat dissipating parts 132 and 134 are also modified according to the rectangular shape of the electrical steel sheet, but as described above, the method of forming an angle equal to 1/3 of the angle between the midpoints of the respective outer line segments 110 is always the same.

In this case, in order to further increase the heat dissipation efficiency, a third heat dissipation part 135 may be additionally formed between the first and second heat dissipation parts 132 and 134 as shown in the drawing.

The third heat dissipation part 135 is also located at a point symmetrically with respect to the reference line, and the angle between the formation position and the third heat dissipation part 135 is not very important, but when it is stacked, all of the third heat dissipation part 135 is exposed from the front electrical steel sheet. Each of the third heat dissipation parts 135 may communicate with each other back and forth.

In addition, the groove 140 is formed at an intermediate point of the inclined surface 122, that is, a point crossing the reference line D of the inclined surface 122 to face the center point. Welded area between each disk.

At this time, the depth of formation of the groove 140 is such that the distance from the center point to the inner bottom of the groove 140 is equal to the distance (F) from the center point to each intermediate line segment 110.

In the center of the electrical steel sheet 100, an installation hole 150 in which a rotor is positioned is formed, and an insertion groove 152 into which a stator winding (not shown) is fitted is formed at an edge of the installation hole 150, and each insertion groove ( 152 are formed at intervals that may be in communication with the insertion groove of the other electrical steel sheet even if the electrical steel sheets are laminated in a rotated state.

The electrical steel sheet is basically laminated back and forth along the rotor shaft direction, in which the laminated steel sheet is rotated by a predetermined angle rather than simple lamination.

That is, the first electrical steel sheet 100 is stacked on the bottom thereof, and the second electrical steel sheet 200 is laminated thereon in a state that is rotated 30 ° clockwise than the first electrical steel sheet, and the third electrical steel sheet 300 is disposed thereon. The silver is laminated in a state that is rotated 30 ° clockwise than the second electrical steel sheet 200, the fourth electrical steel sheet 400 is laminated in a state that is rotated 30 ° clockwise than the third electrical steel sheet (300). Thus, the rotated state of the fourth electrical steel sheet and the first electrical steel sheet is the same. This is because the angle between each outline of the electrical steel sheet is 90 degrees. As described above, when the electrical steel sheet is a quadrangular shape, the electrical steel sheet may be rotated and stacked at 30 ° increments, that is, 1/3 of the angle B between the respective edge segments 110. The angle between both ends of the inclined surface 122 and the angle between the first and second heat dissipating parts 132 and 134 and the rotation angle are set to an angle corresponding to 1/3 of the angle between the respective edge segments 110.

As a result, the first heat dissipation portion and the second heat dissipation portion of each electrical steel sheet are in a state of communicating with each other in the front-rear direction, and in this state, air is circulated into each heat dissipation portion to increase heat dissipation efficiency, and the inclined surface of the third electrical steel sheet They are located on the left side with respect to the vertical center line G, so that the inclined surfaces and the third heat dissipating portions of the second and third electrical steel sheets are positioned in left and right symmetry with respect to the vertical center line.

Referring to FIG. 3, the inclined surfaces of the first, second and third electrical steel sheets all protrude outwards, but do not overlap each other, and are sequentially arranged. The overall stacked shape is circular by the outer arc of each inclined surface. In addition, the third heat dissipation portion and the grooves of the third electrical steel sheet 300 are also exposed to the upper portion of the outer edge of the second electrical steel sheet 200 in a state located on the right side with respect to the vertical center point. Since the distance between and the distance to the middle point of each line segment is the same, the bottom surface of the grooves of the third electrical steel sheet 300 coincides with the respective outer segment of the second electrical steel sheet 200.

In this state, the lamination state between the second and third electrical steel sheets 200 and 300 is fixed by welding the coincidence points between the groove bottom surfaces of the third electrical steel sheets 300 and the respective edge portions of the second electrical steel sheets 200. In the same manner, the first and second electrical steel sheets 100 and 200 are welded. As a result, all of the first, second and third electrical steel sheets 100, 200 and 300 are integrated.

Thereafter, the fourth electrical steel sheet 400 rotated by 90 ° with respect to the first electrical steel sheet 100 is laminated in the same state as the first electrical steel sheet 100, and the electrical steel sheets thereafter have the same shape as the previous structure. Repeatedly stacked. Further, the electrical steel sheets to be laminated later are all welded to each other in the same manner, so that the whole stator is integrated. Therefore, not only a supporting rod for maintaining the overlapping state between the electrical steel sheets, but also a support frame for preventing the shaking between the electrical steel sheets is not necessary. The installation structure is simpler than before, and the space occupied by the support rod and the support frame can be saved.

As described above, according to the present invention, each electrical steel sheet constituting the stator is manufactured in an octagonal shape, but the edge portions of the electrical steel sheets, that is, the inclined surfaces, are all protruded outward as they are sequentially rotated while being gradually increased at a predetermined angle. The biggest feature is that the heat dissipation area can be secured. This can lower the heat generation of the generator and motor. In addition, it is one of the other features to further increase the heat radiation efficiency by forming a moving path of the air by the heat radiating portion communicating with each other in the lamination process.

In addition, by improving the structure of each of the electrical steel sheet to enable the mutual connection, it is also characterized in that it can be installed without a separate support rod and support frame. Raw materials used in the production of generators and motors can be reduced, and manufacturing costs can be lowered.

The basic structure of manufacturing an electrical steel sheet in a square shape and laminating it sequentially by a predetermined angle is the same as in the previous embodiment, but there is a difference in that the inclined surface is not formed in the corner portion of the electrical steel sheet.

Therefore, this structure also has a corner portion protruding to the outside. Of course, in this case, the exterior is not circular when viewed from the front, but the space charge in the case is relatively large. However, a large area is protruded compared to the case where the inclined surface is formed. have.

Claims (1)

Rotating a 0.5 mm thick square steel sheet to cut it in a circle using a cutter;
Cutting the upper, lower, left, and right sides of the circular electrical steel sheet to form octagons in which the 1st, 3rd, 5th, 7th sides are straight, and the 2nd, 4th, 6th, 8th sides are arcs of a certain curvature;
Respectively forming a plurality of heat dissipating parts so as to be symmetrical to both sides of a reference line dividing an angle between adjacent intermediate points from a center point of the electrical steel sheet;
15 ° twisted to both sides with respect to the reference line to be both end points of the inclined surface of the second, fourth, sixth, and eighth arc shape, the angle between the two end points of the inclined surface forms a 30 ° relative to the center point, and the reference line Forming first and second heat dissipating parts at points symmetrically with respect to the first and second radiating parts, and forming a third heat dissipating part so as to communicate with the front and rear at the same time as being exposed from the front disc when stacked; And forming an installation hole in the center of the electrical steel sheet formed at an edge at which the insertion groove into which the stator winding is fitted is inserted into the groove of the elliptical plate at intervals that can be communicated with each other. Forming a;
Stacking the plurality of electrical steel sheets by repeatedly forming at least a thousand electrical steel sheets and repeatedly laminating the electrical steel sheets by rotating them clockwise by 30 ° from the bottom to the upper ones of the formed electrical steel sheets;
Forming a groove at an intermediate point of each inclined surface of the electrical steel sheet to face the center point; Forming a depth of the groove so that a distance from a center point to a bottom surface of the groove is equal to a distance from an intermediate point of the outer line segment;
A laminated stator forming step of welding the formed grooves to manufacture a plurality of electrical steel sheets as a laminated stator;
A winding step of forming a winding having a pair of in-slot predetermined portions corresponding to the in-slot arrangement portions and a pair of coil end predetermined portions corresponding to the coil end arrangement portions;
A convex forming step of forming the coil end predetermined part into a convex shape protruding in the circumferential direction of the winding;
A crank forming step of forming a step of a width size of the electrical steel sheet in a stacking direction of the electrical steel sheet in the coil end plan portion;
An open molding step of molding such that the distance between the predetermined portions in the pair of slots is gradually increased with respect to the stacking direction of the electrical steel sheet;
An arc shaping step of forming an arc-shaped portion that is curved in the lamination direction of the electrical steel sheet on one or both of the coil end scheduled portions of the pair of coil end scheduled portions;
The winding step such that the lamination direction of the electrical steel sheet in one coil end predetermined portion and the lamination direction of the electrical steel sheet in the other coil end predetermined portion are perpendicular to each other for the pair of coil end scheduled portions. A core forming step comprising a 90 ° bending forming step of performing bending forming on the winding formed in the above;
Connecting the grooves of the formed stacked stator to be in contact with the housing;
A generator and a motor manufacturing step comprising the step of including the core inside the housing so as to be interlocked with the stacked stator.
The groove of the stator is used as a ventilation path having a branch path for branching the flow in the direction of the center point,
The core forming step
Mounting an insulator including a first slot into which a first power terminal is inserted and a second slot into which a neutral terminal is inserted into a stator core having a plurality of teeth formed in a radial shape, and winding the coil on the insulator;
An upper insulator covering and insulating the upper portion of the tooth and having an upper coupling portion formed inwardly and having an upper coupling hole formed therein;
A lower insulator covering and insulating the lower portion of the tooth and having a lower coupling portion formed inwardly and having a lower coupling hole formed therein;
A coil wound around a tooth portion which is covered and insulated by the upper and lower insulators and connected between adjacent teeth;
And a coil protection cover covering an upper portion of the connected portion of the coil such that the coils connected between the adjacent teeth are not exposed to the outside.

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