TWI548181B - Commutator motor, electric blower, electric cleaner, and method for manufacturing commutator motor - Google Patents

Description

Commutator motor, electric blower, electric vacuum cleaner and commutator motor Method

The present invention relates to a commutator motor, an electric blower, an electric vacuum cleaner, and a method of manufacturing a commutator motor.

An electric blower in which the blower unit and the electric motor are integrated is known. The electric blower is mounted on an electric vacuum cleaner or the like. Generally, the electric blower is used at a high speed of 30,000 to 45,000 rpm. Therefore, in the electric blower, a commutator motor including a stator including two magnetic poles and a field winding, and a rotor having an armature winding and a commutator located inside the stator is used.

In the conventional electric blower, the stator core has a substantially square frame shape, and has a substantially crescent-shaped magnetic pole that protrudes from the opposite sides of 180° to the inner side. The magnetic flux flows from the surface of the stator core across the gap between the stator core and the opposing surface of the rotor core, enters the tip end of one of the magnetic poles, and is separated into two loops on the back side of the magnetic pole, and passes through the yoke and merges to the back of the other magnetic pole. Then, from the tip of the magnetic pole of the other side across the gap between the stator core and the opposite surface of the rotor core, enter the rotor core, traverse the rotor core in the direction connecting the two magnetic poles, return to the starting position, and wrap around ring. In addition, the yoke stator core There are no two sides of the magnetic pole. At the root of the magnetic pole and the corner of the frame, the magnetic flux gradually changes direction while drawing an arc. That is, in the conventional stator core, the direction of the magnetic flux changes at each position in the stator core. Therefore, as a material of the stator core, a non-directional magnetic steel sheet having magnetic directionality is generally used. That is, the stator core is formed by laminating the non-oriented electrical steel sheets punched by the punch in the axial direction of the motor. The rolling direction of the magnetically oriented grain-oriented electrical steel sheet is called the easy magnetization direction, and the magnetic properties are superior to those of the non-oriented electrical steel sheet. On the other hand, the direction perpendicular to the rolling direction of the grain-oriented electrical steel sheet is magnetically inferior to that of the non-oriented electromagnetic steel sheet. In the case where the directional magnetic steel sheet is used for the conventional stator core, the efficiency of the magnetic circuit is improved in the portion where the direction of the magnetic flux coincides with the direction of easy magnetization, compared with the case where the non-oriented electrical steel sheet is used. The efficiency of the magnetic circuit is reduced. result. As a whole, the efficiency of the magnetic circuit is reduced, and the efficiency of the motor is lowered. Therefore, in the conventional stator core system, it is difficult to use a grain-oriented electrical steel sheet.

Patent Document 1 discloses a technique in which a plurality of components including a laminated grain-oriented electrical steel sheet are combined to form a stator core, and the direction of the magnetic flux and the direction of easy magnetization are slightly matched in each unit.

[Prior patent documents]

[Patent Literature]

Patent Document 1: Japanese Laid-Open Patent Publication No. 2010-093945

The technique of Patent Document 1 has the following problems. At the root of the magnetic pole of the stator core and the corner portion of the frame, the magnetic flux is curved on one side. Gradually change direction. In these portions, the direction of the magnetic flux does not sufficiently coincide with the direction of easy magnetization. Therefore, in the technique of Patent Document 1, the efficiency of the magnetic circuit cannot be sufficiently improved. Further, in the joint surface of the module, that is, the split surface of the stator core, the deformation caused by the punching of the grain-oriented electrical steel sheet of the punch is present at the boundary between the split surfaces, and the magnetic properties are reduced in the region. In the technique of Patent Document 1, the split surface of the stator core exists at the root of the magnetic pole and the corner portion of the frame. Therefore, since all of the magnetic flux traverses the split surface of the stator core, the regions on both sides of the split surface with low magnetic properties are affected by the decrease in efficiency. In the technique of Patent Document 1, in order to sufficiently match the direction of the magnetic flux with the easy magnetization direction, it is necessary to divide the stator core into more components. However, the more the components of the stator core are divided, the more the number of the split faces of the stator core is increased, so that the effect of the efficiency reduction caused by the split faces of the stator core is greater, and the efficiency of the magnetic circuit cannot be sufficiently improved. .

The present invention has been made in order to solve the problems as described above, and an object of the invention is to provide a commutator motor, an electric blower, and an electric vacuum cleaner which can sufficiently improve the efficiency of a magnetic circuit of a commutator motor having a stator core using a grain-oriented electrical steel sheet. And a method of manufacturing a commutator motor.

The commutator motor of the present invention includes: a stator having a stator core and a field winding; and a rotor having an armature winding disposed on an inner side of the stator, wherein the stator core is a strip-shaped direction in which the longitudinal direction is an easy magnetization direction The electromagnetic steel plate is laminated, and the normal line of the surface of the directional electromagnetic steel plate is perpendicular to the rotation axis of the rotor, and the stator core is divided into the first stator core and the second stator core by the core split surface, and the closer to the core split surface, Laminated directional electromagnetic steel sheet The number of layers is reduced.

According to the present invention, the efficiency of the magnetic circuit of the commutator motor having the stator core using the grain-oriented electrical steel sheet can be sufficiently improved.

1‧‧‧Electric blower

2‧‧‧Air blower department

3‧‧‧ commutator motor

4‧‧‧Fan

5‧‧‧Fan Guides

6‧‧‧Rack

7‧‧‧ Stator

8‧‧‧Rotor

9‧‧‧ Stator core

9A‧‧‧1st stator core

9B‧‧‧2nd stator core

10‧‧‧Field winding

11‧‧‧Axis

12‧‧‧Rotor core

13‧‧ ‧ commutator

14, 15‧ ‧ bearing

16‧‧‧End

17‧‧‧ armature winding

18‧‧‧ sector

19‧‧‧ brushes

20‧‧‧ gap

21‧‧‧ bracket

22, 24‧‧‧Insulating components

23‧‧‧Wedge

25a, 25b‧‧‧core split surface

26a, 26b‧‧‧ magnetic pole

27‧‧‧Iron fixed fixture

28‧‧‧wing arm

29‧‧‧Nozzles

30, 31, 32, 33‧‧‧ areas

34‧‧‧Metal wire

40‧‧‧Electric vacuum cleaner

41‧‧‧ vacuum cleaner body

42‧‧‧Inhalation

43‧‧‧Dust collection department

44‧‧‧Export

91A, 92A, 91B, 92B‧‧‧ magnetic pole

93A, 93B‧‧‧ Winding Installation Department

94‧‧‧Directional electromagnetic steel sheet

100, 110‧‧‧ devices

101‧‧‧ coil material

102‧‧‧Roller

103, 112‧‧‧ Roller feeder

104‧‧‧Cutter

105‧‧‧Discharge agencies

113‧‧‧Bending processing rolls

941‧‧‧ end

Fig. 1 is a longitudinal sectional view showing an electric blower according to a first embodiment of the present invention.

Fig. 2 is a cross-sectional view showing the main part of the commutator motor according to the first embodiment of the present invention as seen from the side of the blower unit in the direction of the rotation of the motor.

Fig. 3 is a view in which only the stator core is taken out from Fig. 2.

Fig. 4 is an example of magnetic field lines of the commutator motor according to the first embodiment of the present invention, which is obtained by electromagnetic field analysis.

Fig. 5 is a schematic view showing an airfoil winding machine which is an example of an automatic machine which performs alignment winding of a field winding.

Fig. 6 is a cross-sectional view showing the main part of the commutator motor according to the second embodiment of the present invention as seen from the side of the blower unit in the direction of the rotation of the motor.

Fig. 7 is a view in which only the stator core is taken out from Fig. 6.

Fig. 8 is an example of magnetic field lines of the commutator motor according to the second embodiment of the present invention obtained by electromagnetic field analysis.

Fig. 9 is a schematic view showing an example of a cutting step of the method of manufacturing a commutator motor according to the third embodiment of the present invention.

Fig. 10 is a schematic view showing an example of a bending process of a method of manufacturing a commutator motor according to a third embodiment of the present invention.

Figure 11 is a cross-sectional view showing a vacuum cleaner according to a fourth embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same reference numerals will be given to the same elements, and overlapping description will be omitted. Further, the present invention includes all combinations of the embodiments shown hereinafter.

First embodiment

Fig. 1 is a longitudinal sectional view showing an electric blower according to a first embodiment of the present invention. As shown in Fig. 1, the electric blower 1 of the first embodiment has a blower unit 2 that generates a suction force, and a commutator motor 3 that drives the blower unit 2. The electric blower 1 is applicable to, for example, an electric vacuum cleaner.

The blower unit 2 includes a fan 4 having a plurality of fins and a fan guide 5 covering the fan 4. The fan guide 5 guides the air flowing along with the rotation of the fan 4 to the inside of the commutator motor 3. The flowing air is discharged from the opening (not shown) provided in the frame 6 while cooling the commutator motor 3 that generates heat due to the operation.

The commutator motor 3 includes a stator 7 that is fixed to the inside of the cup-shaped or cylindrical frame 6 and a rotor 8 that is disposed opposite to the inside of the stator 7 via the gap 20 . The stator 7 has a magnetic field. The rotor 8 is rotatably supported and has an armature function. A part of the commutator motor 3 that is not housed inside the frame 6 extends from the opening or the notch formed in the frame 6 to the outside.

The stator 7 includes a stator core 9 which is formed by laminating a plurality of directional electromagnetic steel sheets, and a field winding 10 wound through the insulating member 24. In the stator core 9. A magnetic field is generated inside the stator 7 by flowing a current to the field winding 10.

The rotor 8 includes: a shaft 11 disposed at the center; an annular rotor core 12 fixed to the periphery of the shaft 11; an armature winding 17 wound around the rotor core 12 via the insulating member 22; and a commutator 13 attached thereto A position separated from the rotor core 12 is fixed around the shaft 11. The rotor core 12 is formed by laminating a plurality of electromagnetic steel sheets. The shaft 11 is supported by the frame 6 via bearings 14, 15. Thereby, the rotor 8 can rotate the frame 6 freely. The bearing 14 located on one side of the blower unit 2 is housed in a bracket 21 that is disposed to straddle the opening of the frame 6. The other bearing 15 located on the side opposite to the side of the blower unit 2 is housed in the bottom of the frame 6.

The fan 4 is fixed to the end portion 16 of the shaft 11 on the blower portion 2 side. The fan 4 is driven to rotate as the rotor 8 rotates. The opening end of the plurality of coils constituting the armature winding 17, that is, the end point and the end of the winding start, that is, the end point of the winding end is welded, that is, the method of heat riveting, etc., and the segment 18 of the commutator 13 is electrically connection. A pair of brushes 19 are held by the frame 6, and are pressed against the commutator 13 by a spring, and are in sliding contact with the commutator 13. The brush 19 is connected to a power source (not shown), and supplies a current, that is, an armature current, to the armature winding 17 via the commutator 13. Further, the field winding 10 is connected in series with the armature winding 17, and current is also supplied to the field winding 10 from the same power source. The rotational torque generated in the rotor 8 is generated by the magnetic field generated by the stator 7 and the armature current. In order to fix the rotation direction of the rotor 8, the armature winding 17 and the sector piece 18 are wired to match the phase of the rotor 8, and the coil through which the armature current flows is switched.

Fig. 2 is a side view of the blower unit 2 from the direction of the rotation axis of the rotor 8. A cross-sectional view of a main part of the commutator motor 3 according to the first embodiment of the present invention is shown. Fig. 3 is a view in which only the stator core 9 is taken out from Fig. 2 . The direction of rotation of the rotor 8 can be set by a combination of the connection of the armature winding 17 and the sector 18. The direction of rotation of the rotor 8 is determined by the direction of the wings of the blower unit 2. In the first embodiment, the rotation direction of the rotor 8 is turned to the left in the second drawing, that is, in the counterclockwise direction.

As shown in the second and third figures, the stator core 9 is formed in a ring shape as viewed in the direction of the rotation axis of the rotor 8. The stator core 9 is divided into a first stator core 9A and a second stator core 9B by dividing the core split surfaces 25a and 25b at two positions. The first stator core 9A and the second stator core 9B have a substantially C-shape. The core split surfaces 25a and 25b are located rearward of the center line of the magnetic poles of the stator core 9 in the direction of rotation of the rotor 8 as viewed in the direction of the rotation axis of the rotor 8. In the first embodiment, the core split surfaces 25a and 25b are located in the vicinity of the direction perpendicular to the electrical neutral axis of the commutator motor 3 during the rated operation. In the following description, the electrical neutral axis at the time of rated operation of the commutator motor 3 is simply referred to as an "electric neutral axis". In the first embodiment, the core split surfaces 25a and 25b are perpendicular to the electrical neutral axis and are located at or near the plane passing through the center of the rotor 8. The core split faces 25a, 25b are located rearward of the rotor 8 in the direction of rotation of the rotor 8, which means that the core split faces 25a, 25b are located at an acute angle from the magnetic pole center line in a direction opposite to the direction of rotation of the rotor 8. After the location.

The first stator core 9A has a magnetic pole portion 91A on the side of the core split surface 25a, a magnetic pole portion 92A on the side of the core split surface 25b, and a winding attachment portion 93A between the magnetic pole portions 91A and 92A. The second stator core 9B has The magnetic pole portion 91B on the side of the core split surface 25b, the magnetic pole portion 92B on the side of the core split surface 25a, and the winding attachment portion 93B located between the magnetic pole portions 91B and 92B. The magnetic pole portions 91A, 92A, 91B, and 92B constitute a circular arc shape centering on the rotation axis of the rotor 8. The field winding 10 is wound via the insulating member 24 in the winding attachment portion 93A of the first stator core 9A and the winding attachment portion 93B of the second stator core 9B. The armature winding 17 wound around the rotor core 12 via the insulating member 22 is prevented from falling off by the wedge 23.

As shown in FIG. 3, the magnetic pole portion 91A of the first stator core 9A and the magnetic pole portion 92B of the second stator core 9B form one magnetic pole 26a of the stator core 9. The magnetic pole portion 92A of the first stator core 9A and the magnetic pole portion 91B of the second stator core 9B form the other magnetic pole 26b of the stator core 9. The inner peripheral sides of the magnetic poles 26a and 26b are opposed to the rotor 8 through a predetermined gap 20. The center of the length of the magnetic pole 26a in the circumferential direction around the rotation axis of the rotor 8 and the center of the length of the magnetic pole 26b in the circumferential direction around the rotation axis of the rotor 8 are connected to a magnetic pole center. line. In the first embodiment, the core split surfaces 25a and 25b are inclined with respect to the magnetic pole center line. However, it is not limited to such a configuration, and the core split faces 25a, 25b may be located at the position of the magnetic pole center line.

The first stator core 9A and the second stator core 9B have a shape that bulges outward from the center line of the magnetic pole in a substantially vertical direction. The winding attachment portions 93A, 93B that wind the field winding 10 are formed by the swollen shape. The winding attachment portions 93A, 93B are located farther from the rotation axis of the rotor 8 than the magnetic pole portions 91A, 92A, 91B, 92B. The region 30 is formed between the winding attachment portion 93A and the outer circumference of the rotor 8, and the region 31 is formed between the winding attachment portion 93B and the outer circumference of the rotor 8. The field winding 10 is used in the region 30 and mounted with windings The portion 93A is located in the region 32 on the opposite side of the region 30, and is wound around the winding attachment portion 93A in a ring shape. Similarly, the field winding 10 is a region 31 for use, and a region 33 located on the opposite side of the region 31 with the winding attachment portion 93B interposed therebetween, and is wound around the winding attachment portion 93B in a ring shape.

The winding direction of the field winding 10 is indicated by a dot mark and a cross mark in Fig. 2 . The dot mark indicates the flow of current from the depth of the paper to the front side, and the cross mark indicates the flow of current from the front side of the paper to the depth. Alternatively, the winding direction of the field winding 10 may be combined with the reverse direction of the example of Fig. 2 . Further, as the winding direction of the field winding 10, in addition to the toroidal winding, there is also a manner of avoiding interference with the rotor 8 from the region 30 to the region 31, and avoiding interference with the rotor 8 by the rotor 8 The opposite side of the direction of the rotation axis is returned from the region 31 and returned to the region 30, and the method of repeating the predetermined number of turns is repeated. This method has the advantage of not having regions 32, 33 compared to annular winding. On the other hand, this method has a drawback that not only the alignment winding is difficult, but also the winding length is long because the rounded shape of the coil end to avoid interference with the rotor 8 is used. Therefore, in general, there are many cases where ring winding is a preferred choice.

The magnetic flux generated by the field winding 10 is in the direction of the magnetic pole center line between the magnetic poles 26a, 26b. The electrically neutral axis is an axis perpendicular to the direction of the direction of the resultant magnetic flux of the magnetic flux generated by the field winding 10 and the magnetic flux generated by the armature winding 17. The direction of the right angle of the electrically neutral axis is offset from the centerline of the magnetic pole to the rear of the direction of rotation of the rotor 8. Therefore, the positions of the two core split surfaces 25a and 25b and the magnetic pole center line are set in accordance with the balance of the magnetic flux generated by each of the field winding 10 and the armature winding 17. Specifically, it may be determined by using a magnetic field analysis or a result of a test evaluation.

The stator core 9 is formed by laminating a plurality of strip-shaped grain-oriented electrical steel sheets 94 that have been bent. The longitudinal direction of the strip-shaped grain-oriented electrical steel sheet 94 is an easy magnetization direction. Further, the normal line of the surface of each of the directional electromagnetic steel sheets 94 stacked is perpendicular to the rotation axis of the rotor 8. In other words, when the laminated direction of the grain-oriented electrical steel sheet 94 is viewed from the direction of the rotation axis of the rotor 8, the longitudinal direction of the magnetic path of the stator core 9 is substantially perpendicular. Further, the direction of easy magnetization of the grain-oriented electrical steel sheet 94 becomes a direction along the magnetic path. The thickness of the layer of the grain-oriented electrical steel sheet 94 corresponds to the magnetic path width (the width of the magnetic pole and the yoke) of the stator core 9 when viewed from the direction of the rotation axis of the rotor 8. Further, the width of the strip-shaped grain-oriented electrical steel sheet 94, that is, the length in the short-side direction corresponds to the length of the stator core 9 in the direction of the rotation axis of the rotor 8.

Each of the plurality of strip-shaped grain-oriented electrical steel sheets 94 constituting the first stator core 9A is continuously formed from the magnetic pole portion 91A via the winding attachment portion 93A to the magnetic pole portion 92A. In the same manner, each of the plurality of strip-shaped grain-oriented electrical steel sheets 94 of the second stator core 9B is continuously formed from the magnetic pole portion 91B via the winding attachment portion 93B to the magnetic pole portion 92B.

Fig. 4 is an example of magnetic field lines of the commutator motor 3 of the first embodiment obtained by electromagnetic field analysis. As shown in Fig. 4, the magnetic field lines of the stator core 9 are along the longitudinal direction of the grain-oriented electrical steel sheet 94 except for the vicinity of the core split surfaces 25a and 25b, that is, the direction of easy magnetization. In particular, the curved portion between the magnetic pole portions 91A, 92A and the winding attachment portion 93A and the curved portion between the magnetic pole portions 91B, 92B and the winding attachment portion 93B also have the direction of the magnetic flux and the longitudinal direction of the grain-oriented electromagnetic steel sheet 94. That is, the direction of easy magnetization is approximately the same. The grain-oriented electromagnetic steel sheet 94 is excellent in magnetic properties in the direction of easy magnetization, and its right angle direction The magnetic properties are poor. According to the commutator motor 3 of the first embodiment, it is possible to increase the degree of matching between the direction of the magnetic flux of the stator core 9 and the direction of easy magnetization of the grain-oriented electrical steel sheet 94 without increasing the number of divisions of the stator core 9. Therefore, in the stator core 9, since the magnetic properties of the grain-oriented electromagnetic steel sheet 94 can be mainly used only, the efficiency of the magnetic circuit can be improved. As a result, the efficiency of the commutator motor 3 and the electric blower 1 can be improved.

Further, in the first embodiment, when viewed from the direction of the rotation axis of the rotor 8, the core split surfaces 25a and 25b of the stator core 9 are located in the position opposite to the direction of rotation of the rotor 8 with respect to the magnetic pole center line, and particularly in electrical properties. In the vicinity of the right-angle direction of the axis, the effect as shown below can be obtained. As shown in Fig. 4, the lines of magnetic force are divided into two loops of a loop around the left side and a loop around the right side via a line connecting the core split faces 25a, 25b in the vicinity of the right angle direction of the electrically neutral axis. Therefore, the magnetic flux system does not traverse the core split faces 25a, 25b. Therefore, in the first embodiment, since the influence of the decrease in efficiency caused by the magnetic flux crossing the split surface of the stator core 9 is surely suppressed, the efficiency of the magnetic circuit is further improved.

Further, since the magnetic flux density is low in the vicinity of the core split surfaces 25a and 25b, even if the core split surfaces 25a and 25b are slightly deviated from the direction perpendicular to the electrical neutral axis, the influence is small. In other words, even if the core split surfaces 25a and 25b are slightly deviated from the direction perpendicular to the electrical neutral axis, the same effects as described above can be obtained. Therefore, even if the balance of the magnetic flux caused by the fluctuation of the load during the operation of the commutator motor 3 or the like changes slightly, the electrical neutral axis slightly deviates. Further, for the purpose of improving the rigidity of the stator core 9 and improving the grouping of the commutator motor 3, it is also possible to use the field splitting surface after the field winding 10 is mounted. 25a and 25b are joined by a method of welding or bonding the first stator core 9A and the second stator core 9B. Since the influence on the magnetic flux is small in the case of the joint, the same effect as described above can be obtained.

Further, with the rotation of the rotor 8, the magnetic lines of force relatively rotate the rotor core 12. Therefore, the rotor core 12 is preferably constructed of a non-oriented electrical steel sheet. In other words, it is preferable to form the rotor core 12 by laminating a plurality of sheets of the non-oriented electrical steel sheets in the direction of the rotation axis of the rotor 8. Further, in the first embodiment, the stator core 9 is divided into the first stator cores. The 9A and the second stator core 9B can easily perform the aligned winding of the field winding 10. Fig. 5 is a schematic view showing an wing winding machine which is an example of an automatic machine which performs alignment winding of the field winding 10. The wing winding machine shown in Fig. 5 has a core fixing jig 27 for fixing the first stator core 9A or the second stator core 9B, and a wing arm 28 having a nozzle 29 having a guide wire 34 at the tip end. . The core fixing jig 27 fixes the first stator core 9A or the second stator core 9B so that the rotation axis of the wing arm 28 coincides with the central axis of the winding attachment portion 93A or 93B. The wire 34 is drawn through the inside of the blade arm 28 and then withdrawn from the nozzle 29. The wing arm 28 moves in the direction of the rotation axis while rotating. By the wing winding machine, the wire 34 is wound around the winding attachment portion 93A of the first stator core 9A or the winding attachment portion 93B of the second stator core 9B, whereby the field winding 10 can be formed. The control for placing the position of the wire 34 is performed by synchronously controlling the movement of the wing arm 28 and the direction of the rotation axis. However, since the metal wire 34 generally uses a copper wire or an aluminum wire having a diameter of 2 mm or less, the rigidity is small. Moreover, the bending property remains in the metal wire 34 due to the deformation history of the insertion nozzle 29. Due to these matters, the wire 34 coming out of the outlet of the nozzle 29 does not pen. Straight, and the position where the metal wire 34 is placed is deviated from the desired position, and the alignment winding may be confusing. In order to suppress this phenomenon, the nozzle 29 is as close as possible to the surface on which the metal wire 34 is placed. Therefore, the left and right spaces of the field winding 10 are open, and the nozzle 29 is accessible, which is suitable for alignment winding. In the first embodiment, the stator core 9 is divided into the first stator core 9A and the second stator core 9B, and since the nozzle 29 can be brought close to the winding attachment portion 93A or 93B, the field winding 10 can be easily and accurately performed. Aligned winding. In addition, in the case of the so-called main shaft winding method in which the first stator core 9A or the second stator core 9B is rotated by the fixed nozzle 29, the same effect is obtained, and the same effects as described above can be obtained.

Second embodiment

In the second embodiment of the present invention, the second embodiment of the present invention will be described with reference to the first embodiment, and the same reference numerals will be given to the same or corresponding parts, and the description will be omitted.

Fig. 6 is a cross-sectional view showing the main part of the commutator motor 3 of the second embodiment from the side of the blower unit 2 in the direction of the rotation of the motor 8. Fig. 7 is a view in which only the stator core 9 is taken out from Fig. 6. As shown in Fig. 6 and Fig. 7, in the second embodiment, the magnetic pole portions 91A, 92A, 91B, and 92B of the stator core 9 are laminated with the grain-oriented electrical steel sheets close to the core split surfaces 25a and 25b. The number of layers of 94 is gradually reduced. Further, in the magnetic pole portions 91A, 92A, 91B, and 92B of the stator core 9, the end portions 941 of the plurality of layers of the grain-oriented electrical steel sheet 94 are opposed to the rotor 8, respectively. That is, the end portion 941 of each layer of the laminated grain-oriented electrical steel sheet 94 is formed to face the rotor 8, that is, the inner circumferential surface of the stator core 9. The layer on the inner side of the magnetic pole portions 91A, 92A, 91B, and 92B, and the distance between the end portion 941 of the grain-oriented electrical steel sheet 94 and the core split surfaces 25a and 25b Big. The closer to the core split faces 25a, 25b, the gradually smaller the width of the magnetic path of the stator core 9.

According to the second embodiment, the magnetic fluxes are more evenly spaced from each other, and the magnetic flux density in each of the grain-oriented electrical steel sheets 94 is more uniform. Therefore, the magnetic flux density is more uniform than that of the first embodiment. The degree of coincidence of the direction of the magnetic flux with the direction of easy magnetization of the grain-oriented electromagnetic steel sheet 94 is increased. In the second embodiment, the core split surfaces 25a and 25b are inclined with respect to the magnetic pole center line. However, the configuration is not limited to this configuration, and the core split surfaces 25a and 25b may be disposed at the position of the magnetic pole center line. Even if the core split surfaces 25a and 25b are disposed at the position of the magnetic pole center line, the closer the core split surfaces 25a and 25b are, the smaller the number of layers of the laminated grain-oriented electrical steel sheets 94 can be, and the above-described similar effects can be obtained. In the second embodiment, the structure in which the layer from the inner side of the laminated grain-oriented electrical steel sheet 94 is sequentially reduced to the outer layer is preferably closer to the core split surfaces 25a and 25b.

Fig. 8 is an example of magnetic field lines of the commutator motor 3 of the second embodiment obtained by electromagnetic field analysis. As shown in Fig. 8, the lines of magnetic force are divided into two loops of a loop around the left side and a loop around the right side via a line connecting the core split faces 25a, 25b in the vicinity of the right angle direction of the electrically neutral axis. The magnetic lines of force from the rotor core 12 to the stator core 9 near the core split surface 25a are from the stator core 9 to the rotor core 12 near the core split surface 25b. The magnetic lines of force from the rotor core 12 to the stator core 9 at a distance from the core split face 25a are from the stator core 9 to the rotor core 12 away from the core split face 25b. Therefore, the number of lines of magnetic lines of force on the magnetic poles 26a and 26b is small near the core split faces 25a and 25b, and gradually increases as they move away from the core split faces 25a and 25b. In the second embodiment, the closer to the core splitting faces 25a, 25b, The magnetic path width gradually becomes smaller, so that the magnetic lines of force are more evenly spaced from each other, and the magnetic flux density becomes more uniform. In the laminate of the grain-oriented electrical steel sheets 94, the end portion 941 of each of the laminates is formed so as to face the rotor 8, and the inner peripheral surface of the stator core 9 is closer to the core split faces 25a, 25b. The number of layers of the grain-oriented electrical steel sheet 94 is gradually reduced, and the effects as described above can be surely achieved. According to the second embodiment, the efficiency of the magnetic circuit can be improved more than in the first embodiment. As a result, the efficiency of the commutator motor 3 and the electric blower 1 can be further improved. Further, according to the second embodiment, the amount of use of the grain-oriented electrical steel sheet 94 can be reduced, and the commutator motor 3 and the electric blower 1 can be made lighter than the first embodiment.

Third embodiment

In the third embodiment, the third embodiment of the present invention will be described with reference to the third embodiment, and the same reference numerals will be given to the same or corresponding parts, and the description will be omitted.

Fig. 9 is a schematic view showing an example of a cutting step of the method of manufacturing a commutator motor according to the third embodiment of the present invention. Fig. 10 is a schematic view showing an example of a bending process of a method of manufacturing a commutator motor according to a third embodiment of the present invention.

The method of manufacturing a commutator motor according to the third embodiment is a method of manufacturing the commutator motor 3 of the present invention. The commutator motor manufacturing method according to the third embodiment is characterized in that the step of manufacturing the stator core 9 is employed. The step of manufacturing the stator core 9 includes a cutting step, a bending processing step, and a build-up fixing step of the grain-oriented electrical steel sheet 94.

In the cutting step, the grain-oriented electrical steel sheet 94 is cut into a predetermined length. A strip of rectangular shape having a degree L and a width W. The longitudinal direction of the grain-oriented electromagnetic steel sheet 94, that is, the direction of the length L is an easy magnetization direction. The length L of the grain-oriented electrical steel sheets 94 of the respective layers laminated in the first stator core 9A or the second stator core 9B corresponds to the magnetic path length of each layer, and is different from each other. On the other hand, the width W of the grain-oriented electrical steel sheet 94, that is, the length in the short-side direction corresponds to the length of the stator core 9 in the direction of the rotation axis of the rotor 8. Therefore, the width W of the grain-oriented electrical steel sheets 94 of the respective layers is equal. Therefore, when the stator core 9 is manufactured, as shown in Fig. 9, a coil material 101 in which a grain-oriented electrical steel sheet 94 having a slit shape of a width W is wound in advance is prepared. The apparatus 100 used in the cutting step has a uncoiler 102 that extracts the directional electromagnetic steel sheet 94 from the coil material 101, and a roller feeder 103 that is gripped by a pair of rollers and fed out from the uncoiler 102. The directional electromagnetic steel sheet 94; the cutter 104 cuts the short side of the grain-oriented electromagnetic steel sheet 94 fed from the roller feeder 103; and the discharge mechanism 105 discharges the directionality cut by the cutter 104 Electromagnetic steel plate 94. The cutting method can also be any method such as shearing or stamping.

The length L of the grain-oriented electrical steel sheet 94 differs depending on which position is disposed in the stacking direction of the first stator core 9A or the second stator core 9B. Therefore, in the cutting step, it is necessary to change the length L of the grain-oriented electromagnetic steel sheet 94 for each sheet. To cope with this, the device 100 has a servo mechanism that controls the relative position of the cutter 104 in the longitudinal direction of the grain-oriented electrical steel sheet 94. That is, the apparatus 100 has a servo mechanism that controls the feed amount of the grain-oriented electrical steel sheet 94 according to the rotation angle of the roller of the roller feeder 103 and the timing at which the cutter 104 is lowered. The length L of the grain-oriented electrical steel sheet 94 can be controlled by controlling the relative position of the cutter 104 in the longitudinal direction of the grain-oriented electrical steel sheet 94. If you use this type of equipment By the cutting step of 100, each of the grain-oriented electromagnetic steel sheets 94 having a different length L can be produced with high productivity.

Further, the configuration of the servo mechanism for controlling the relative position of the cutter 104 in the longitudinal direction of the grain-oriented electrical steel sheet 94 is not limited to the configuration of the third embodiment. Instead of the configuration of the third embodiment, a configuration in which the cutter 104 is moved in the longitudinal direction of the grain-oriented electrical steel sheet 94 may be employed.

The bending processing step is a step of bending the grain-oriented electrical steel sheet 94 cut at the cutting step with a predetermined bending position and bending radius. As a method of bending, roll bending is suitable. In the bending processing step, as shown in Fig. 10, the roll bending is performed by means of a roll feeder 112 which sandwiches and feeds the grain-oriented electrical steel sheet 94 with a pair of rolls, and a device 110 of a plurality of bending rolls 113. The bending position and the bending radius of the grain-oriented electrical steel sheet 94 differ depending on which position is disposed in the stacking direction of the first stator core 9A or the second stator core 9B. Therefore, in the bending processing step, it is necessary to change the bending position and the bending radius of the grain-oriented electromagnetic steel sheet 94 for each sheet. To cope with this, the device 110 has a servo mechanism that controls the relative position of the bending processing roller 113 of the grain-oriented electromagnetic steel sheet 94. That is, the apparatus 110 has a feed amount for controlling the grain-oriented electromagnetic steel sheet 94 according to the rotation angle of the roller of the roller feeder 112, and moving the bending processing roller 113 relative to the roller feeder 112 in the upper-lower direction in FIG. The servo of the amount of movement. The bending position and the bending radius of the grain-oriented electromagnetic steel sheet 94 can be controlled by controlling the relative amount of the feed amount of the grain-oriented electromagnetic steel sheet 94 by the roller feeder 112 and the bending processing roller 113 to the roller feeder 112. According to the bending processing step using such a device 110, each of the grain-oriented electrical steel sheets 94 having different bending positions and bending radii can be manufactured with high productivity.

Further, the configuration of the servo mechanism for controlling the relative position of the bending processing roller 113 of the grain-oriented electrical steel sheet 94 is not limited to the configuration of the third embodiment. Instead of the configuration of the third embodiment, the configuration in which the roller of the roller feeder 112 is moved in the vertical direction in the tenth drawing with respect to the bending processing roller 113 may be employed. Further, as a bending method other than roll bending, for example, a stamping type bending by a die and a punch is required. However, in order to change the bending position and the bending radius, it is necessary to prepare a plurality of types of dies, which is expensive because it is expensive.

In the build-up fixing step, the plurality of grain-oriented electrical steel sheets 94 formed through the cutting step and the bending step are laminated in a state of being laminated. As a fixing method, there are methods of welding, adhesion, and the like. According to the method as described above, the stator core 9 can be manufactured inexpensively and at high speed. In the method of manufacturing a commutator motor according to the third embodiment, a well-known method can be applied in addition to the step of manufacturing the stator core 9.

Fourth embodiment

In the fourth embodiment of the present invention, the fourth embodiment of the present invention will be described, and the same reference numerals will be given to the same or corresponding parts, and the description will be omitted.

Figure 11 is a cross-sectional view showing a vacuum cleaner according to a fourth embodiment of the present invention. As shown in Fig. 11, the vacuum cleaner 40 of the fourth embodiment includes a cleaner body 41 to which the electric blower 1 of the present invention is mounted, a suction port 42 for sucking outside air into the inside of the cleaner body 41, and a dust collecting portion 43. The dust in the air taken in by the inside of the cleaner body 41 is collected; and the discharge port 44 is discharged to the outside of the cleaner body 41 to exhaust the air taken in the inside of the cleaner body 41. The electric blower 1 generates suction air from the suction port 42 and is discharged from the air The air stream exiting the outlet 44. The air taken in from the suction port 42 is discharged to the outside of the cleaner body 41 via the dust collecting portion 43, the electric blower 1 and the discharge port 44.

As described above, by incorporating the electric blower 1 into the electric vacuum cleaner 40, the efficiency of the electric vacuum cleaner 40 can also be improved. In addition, the case where the electric blower 1 is mounted on the electric vacuum cleaner 40 is described as an example. However, the product to be incorporated in the electric blower 1 of the present invention is not limited to the electric vacuum cleaner 40, and may be incorporated in another product such as a hand dryer. Further, the use of the commutator motor 3 of the present invention is not limited to the electric blower 1 and the electric vacuum cleaner 40, and may be applied to, for example, a power tool, a mixer, an electric coffee mill or the like.

1‧‧‧Electric blower

2‧‧‧Air blower department

3‧‧‧ commutator motor

4‧‧‧Fan

5‧‧‧Fan Guides

6‧‧‧Rack

7‧‧‧ Stator

8‧‧‧Rotor

9‧‧‧ Stator core

10‧‧‧Field winding

11‧‧‧Axis

12‧‧‧Rotor core

13‧‧ ‧ commutator

14‧‧‧ bearing

15‧‧‧ bearing

16‧‧‧End

17‧‧‧ armature winding

18‧‧‧ sector

19‧‧‧ brushes

20‧‧‧ gap

21‧‧‧ bracket

Claims (8)

A commutator motor includes: a stator having a stator core and a field winding; and a rotor having an armature winding disposed on an inner side of the stator, wherein the stator core is a strip-shaped directional electromagnetic having a direction of easy magnetization in a long side direction The normal layer of the grain-oriented electrical steel sheet is perpendicular to the rotation axis of the rotor, and the stator core is divided into the first stator core and the second stator core by the core split surface, and the closer to the core split On the surface, the number of layers of the end layer of the grain-oriented electrical steel sheet is reduced. The commutator motor of claim 1, wherein the stator core has a magnetic pole portion forming a magnetic pole, and a winding mounting portion that is further away from a rotating shaft of the rotor than the magnetic pole portion, the field winding is mounted to the winding Installation department. The commutator motor of claim 1 or 2, wherein the core splitting surface is located in a rotational direction of the rotor with respect to a center line of the pole of the stator as viewed from a direction of a rotation axis of the rotor rear. The commutator motor according to claim 1 or 2, wherein the core splitting surface is located in a direction perpendicular to an electric neutral axis of the commutator motor during rated operation. The commutator motor according to claim 1 or 2, wherein in the magnetic pole portion of the stator core, ends of the plurality of layers of the grain-oriented electrical steel sheet face the rotor. An electric blower comprising: the commutator motor described in claim 1 or 2; and a fan driven by the commutator motor. An electric vacuum cleaner comprising: the electric blower described in claim 6 of the patent application. A method for manufacturing a commutator motor for manufacturing a stator of a commutator motor according to claim 1 or 2, comprising: a cutting step of cutting a strip-shaped directivity in a direction in which a long side is an easy magnetization direction a short side of the electromagnetic steel sheet; a bending processing step of bending the grain-oriented electrical steel sheet cut in the cutting step; and a layer fixing step of fixing the grain-oriented electrical steel sheet bent in the bending step in a laminated state In the cutting step, the length of the grain-oriented electrical steel sheet is controlled by a device having a cutter and a servo mechanism for controlling the position of the cutter in the longitudinal direction of the grain-oriented electrical steel sheet. The bending position and the bending radius of the grain-oriented electrical steel sheet are controlled by a device having a plurality of bending processing rolls and a servo mechanism for controlling the position of the bending processing roller with respect to the grain-oriented electrical steel sheet. The bending process step and the layering fixing step produce the stator core.